Boxboro RibEye 600001 Instructions for use

October 2017

HARDWARE USER MANUAL

RibEye™ Multi-Point Deflection Measurement System:

-Axis Version for the WorldSID 50

Male ATD

Boxboro Systems LLC

978-257-2219

www.boxborosystems.com

October 2017

Table of Contents

Page

1.0 WorldSID RibEye Description ......................................................................................... 5

2.0 RibEye Installation ............................................................................................................ 9

2.1 LED installation ........................................................................................................ 9

2.1.1 LED assemblies ............................................................................................ 10

2.1.2 Mo nting rearward LEDs on the ribs ........................................................... 16

2.1.3 Mo nting center and forward LEDs on the ribs ........................................... 19

2.2 Installing the sensors on the spine ............................................................................ 19

2.3 Order of assembly (LEDs, ribs, and sensors) ........................................................... 23

2.4 Sensor cables ............................................................................................................ 24

2.5 Controller installation .............................................................................................. 25

2.5.1 Mo nting the adaptor plates ......................................................................... 25

2.5.2 Removing the controller end covers ............................................................. 27

2.5.3 Attaching the controller ................................................................................ 28

2.6 Cable ro ting ............................................................................................................ 30

2.6.1 Stat s cable ................................................................................................... 30

2.6.2 D mmy exit cable ........................................................................................ 30

2.6.3 LED cables ................................................................................................... 38

3.0 RibEye Operation ............................................................................................................. 40

3.1 Data coordinate systems ........................................................................................... 40

3.2 Stat s indicator ......................................................................................................... 41

3.3 Ethernet link and activity lights ............................................................................... 41

3.4 Batteries and charger ................................................................................................ 41

3.5 Error codes ............................................................................................................... 43

4.0 RibEye aintenance ........................................................................................................ 45

4.1 D mmy maintenance for RibEye ............................................................................. 45

Appendixes

A. RibEye Specifications and Cable Details ............................................................................ 46

A-1. Meas rement acc racy and range ............................................................................ 46

A-2. Power req irements .................................................................................................. 50

A-3. Data acq isition and storage .................................................................................... 50

A-4. Ethernet comm nication .......................................................................................... 50

A-5. Trigger circ its ......................................................................................................... 51

A-6. Armed-o t circ it ..................................................................................................... 51

A-7. RibEye cable details ................................................................................................. 57

B. Switching RibEye WorldSID from Left-Side to Right-Side Impact ................................... 67

October 2017

List of Figures

Fig re No. Page

1 RibEye sensors mo nted in the d mmy ..................................................................... 5

2 RibEye LEDs mo nted in the d mmy........................................................................ 6

3 RibEye controller with connector covers in place ...................................................... 7

4 RibEye controller with connector covers removed .................................................... 7

5 Controller sensor connectors ...................................................................................... 8

6 Controller connectors for LED cables, stat s cable, and d mmy exit cable .............. 8

7 LED and angled mo nting block ............................................................................... 10

8 LED snapped into angled mo nting block ................................................................ 10

9 Sho lder center LED adaptor plate, inner rib clamp, and foam stopper plate ........... 11

10 Sho lder center LED assembly photo ....................................................................... 12

11 Inner rib clamp plate for thoracic and abdominal ribs............................................... 13

12 Thoracic 1 and abdominal 1 inner rib clamp plate .................................................... 14

13 Thoracic 2, thoracic 3, and abdominal 2 inner rib clamp plate ................................. 14

14 Rearward and forward LED locations ....................................................................... 15

15 Rearward LED placed on do ble-stick tape .............................................................. 16

16 Heat-shrink t bing placed over rearward LED ......................................................... 17

17 Cable ro ting for rearward and center LEDs ............................................................ 18

18 M5 x 10 flat-head cap screw with precision-machined sho lder .............................. 19

19 Sensor base with label ............................................................................................... 20

20 RibEye sensor bases mo nted to spine ...................................................................... 21

21 RibEye sensor front piece .......................................................................................... 22

22 RibEye sensor label on back and alignment pins ...................................................... 22

23 RibEye sensor assemblies mo nted to spine ............................................................. 23

24 Sensor cables ro ted to back of d mmy .................................................................... 24

25 Sensor cables tied to o ter ribs near spine plate ........................................................ 24

26 Sensor cables ro ted over the top sensor and below the neck assembly ................... 25

27 Controller adaptor installed on thoracic 1 rib ............................................................ 26

28 Controller adaptor installed on abdominal 2 rib ........................................................ 26

29 Controller end cover attachment screws .................................................................... 27

30 Controller (sensor connector end) attached to adaptor at thoracic 1 rib .................... 28

31 Controller (cable connector end) attached to adaptor at abdominal 2 rib .................. 29

32 Exit cable connector in RibEye controller ................................................................. 30

33 Cable option for DTS DAS ....................................................................................... 32

34 Cable option for Kistler NXT32 DAS ....................................................................... 33

35 Cable option for generic DAS (separate exit and breako t cables) ........................... 34

36 Cable option for generic DAS (single exit/breako t cable) ...................................... 35

37 Cable option for Kyowa DAS ................................................................................... 36

38 Cable option for Kistler KiH b/KiDa DAS ............................................................ 37

39 Sensor cables tied to controller.................................................................................. 39

October 2017

List of Figures, continued

Fig re No. Page

40 RibEye coordinate system ......................................................................................... 40

41 Battery pack ............................................................................................................... 41

42 RibEye battery pack Cell-Con charger and exit cable charger receptacle ................. 42

43 Plot overlay verifying whether LED moved o t of range ......................................... 44

A1 RibEye meas rement range in X-Y plane – all ribs .................................................. 47

A2 RibEye meas rement range in Y-Z plane – pper three ribs .................................... 48

A3 RibEye meas rement range in Y-Z plane – lower three ribs .................................... 49

A4 Generic trigger inp t circ it ...................................................................................... 52

A5 Trigger inp t config red for DTS MDB-s pplied trigger ......................................... 53

A6 Trigger inp t config red for Kistler NXT32-s pplied trigger .................................. 54

A7 Spare inp t and o tp t circ its .................................................................................. 55

A8 Trigger switch wiring example for generic pigtail cable assemblies ........................ 55

A9 Armed-o t circ it for generic pigtail cable assemblies ............................................. 56

A10 Example of armed-o t indicator light wiring for generic pigtail cable assemblies ... 56

B1 RibEye sensor positions and cable ro ting for right-side impact .............................. 67

List of Tables

Table No. Page

1 S mmary of LED positions and mo nting methods .................................................. 9

2 Sensor base part n mbers and angles ........................................................................ 20

3 Wire colors for breako t cable 70201 and exit/breako t cable 70026 ...................... 38

4 Cell-Con battery charger modes ................................................................................ 42

A1 DTS DAS exit cable 70011 ....................................................................................... 57

A2 Kistler NXT32 DAS exit cable 70020 ....................................................................... 58

A3 Generic DAS exit cable 70025 .................................................................................. 59

A4 Generic DAS breako t cable 70201 .......................................................................... 60

A5 Generic DAS exit/breako t cable 70026 ................................................................... 61

A6 Kyowa DAS exit cable 70027 ................................................................................... 62

A7 KiH b/KiDa exit cable 70028 ................................................................................. 63

A8 LED cables 70001-70006 .......................................................................................... 64

A9 Sensor cables 70001-70006 ....................................................................................... 65

A10 Stat s LED cable ....................................................................................................... 66

October 2017

HARDWARE USER MANUAL

RibEye™ Multi-Point Deflection Measurement System:

-Axis Version for the WorldSID 50th Male ATD

1.0 WorldSID RibEye Description

The RibEye for the WorldSID anthropomorphic test device (ATD) provides X, Y, and Z position data for

18 light-emitting diodes (LEDs) mo nted on the WorldSID ribs. Three LEDs are mo nted on each of the

six ribs. The RibEye for the WorldSID can be mo nted on either side of the d mmy to meas re left-side

or right-side impacts. Appendix A provides the RibEye meas rement range and other specifications,

incl ding details on the cables and connector pino ts. Appendix B explains how to switch the WorldSID

RibEye from left-side to right-side-impact.

Up to 25 seconds of data can be collected at a 10-kHz sample rate. Two types of non-volatile flash

memory are installed in the controller: a Micro-SD card stores all 25 seconds of data from a test, and

onboard flash memory stores 1.7 seconds of data (from –200 ms to 1500 ms) that is retained after power

is t rned off. If external power is lost, the RibEye will operate on internal batteries. Comm nication to

the RibEye is via Ethernet.

Two sets of three sensors monitor the LED positions, as shown in Fig re 1. The top set of sensors ses

red optical filters and monitors the red LEDs mo nted on the first three ribs: the sho lder rib, the thoracic

1 rib, and the thoracic 2 rib. The bottom set of sensors ses bl e optical filters and monitors the bl e

LEDs mo nted on the lower three ribs: the thoracic 3 rib, the abdominal 1 rib, and the abdominal 2 rib.

Figure 1. RibEye sensors mounted in the dummy

(view from pelvis upward)

October 2017

Three RibEye LEDs are mo nted on each rib. Fig re 2 shows the RibEye LEDs installed in the

WorldSID d mmy. The center LEDs are lined p along the d mmy’s left or right side. The forward

LEDs are closer to the front of the d mmy and the rearward LEDs closer to the d mmy’s back.

Figure 2. RibEye LEDs mounted in the dummy

(view from pelvis upward)

The RibEye controller mo nts on the non-str ck side of the d mmy. The controller enclos re also

contains the RibEye’s battery pack. Fig res 3–6 show the following views of the controller:

• Fig re 3 shows the controller as shipped, with connector covers installed at each end.

• Fig re 4 shows the controller with the two end covers removed.

• Fig re 5 shows the connectors for the sensors at one end of the controller.

• Fig re 6 shows the connectors for the LED cables, stat s cable, and d mmy exit cable at the

other end of the controller.

October 2017

Figure . RibEye controller with connector end covers in place

Figure 4. RibEye controller with connector covers removed

October 2017

Figure 5. Controller sensor connectors

Figure 6. Controller connectors for LED cables,

status cable, and dummy exit cable

October 2017

2.0 RibEye Installation

This section explains how to mo nt the RibEye components into the WorldSID 50

Male ATD. The

instr ctions cover the installation of the LEDs, sensors, and controller, as well as the cable ro ting. Some

components are mo nted before the ribs are assembled in the d mmy, and others d ring or after rib

assembly. See section 2.3 below for the specific order of assembly.

2.1 LED installation

Table 1 s mmarizes the LED positions and mo nting methods for all 18 LEDs. The following sections

describe in detail how to mo nt the LED assemblies onto the ribs. The forward LEDs are closer to the

front of the d mmy and the rearward LEDs closer to the d mmy’s back. Please refer back to Fig re 2 for

a vis al showing three LEDs mo nted onto each of the six ribs.

Table 1. Summary of LED positions and mounting methods

Rib

number/type

Rearward LEDs Center LEDs Forward LEDs

Rib #1

(shoulder)

Position Bottom edge of rib

Mounting

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to LED d ptor pl te;

Screw LED d ptor pl te to

cl mp pl te

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

Rib #2

(thor cic 1)

Position Center of rib, mounted fl t

Mounting

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to cl mp pl te

T pe nd he t-shrink

in pl ce

Rib #3

(thor cic 2)

Position Top edge of rib

Mounting

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to ngled block;

Screw ngled block into

cl mp pl te

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

Rib #4

(thor cic 3)

Position Bottom edge of rib

Mounting

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to ngled block;

Screw ngled block into

cl mp pl te

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

Rib #5

( bdomin l 1)

Position Center of rib, mounted fl t

Mounting

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to cl mp pl te

T pe nd he t-shrink

in pl ce

Rib #6

( bdomin l 2)

Position Top edge of rib

Mounting

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

LED ssembly lre dy

glued to ngled block;

Screw ngled block into

cl mp pl te

Sn p LED ssembly

to ngled block;

T pe nd he t-shrink

in pl ce

October 2017

2.1.1 LED assemblies

Fig re 7 shows a LED assembly, with its lead cable attached, and an angled mo nting block. The LED is

soldered onto a metal-clad printed circ it board (MCPCB). Fig re 8 shows the LED assembly snapped

into the angled mo nting block. If the LED does not snap tightly into the angle block, it can be held in

place with s per-gl e (cyanoacrylate) or epoxy.

Figure 7. LED and angled mounting block

Figure 8. LED snapped into angled mounting block

The angled mo nting blocks are sed on fo r of the d mmy’s six ribs – the sho lder, thoracic 2,

thoracic 3, and abdominal 2 ribs. On the sho lder and thoracic 3 ribs, the LEDs are mo nted on the

bottom edge of the ribs. On the thoracic 2 and abdominal 2 ribs, the LEDs are mo nted on the top edge

of the ribs.

On the d mmy’s other two ribs – the thoracic 1 and abdominal 1 – all three LEDs are mo nted flat,

witho t a block. This becomes more clear if yo refer back to Fig re 2, which shows three LEDs mo nted

on each rib.

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