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Flex Pli User Manual

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0% found this document useful (0 votes)

248 views109 pages

Flex Pli User Manual

Uploaded by

Mod Kulabdum

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

Flex PLI GTR

User Manual
For information on Humanetics products, please visit our web site at www.humaneticsatd.com or contact:

Humanetics Innovative Solutions

23300 Haggerty Road
Farmington Hills, MI 48335, USA
Telephone: (+1) 248-778-2171
Fax: (+1) 248-778-2001

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any
means, electronic, photocopying, recording, mechanical or otherwise, without the express written consent of
Humanetics Innovative Solutions.

Copyright © 2018 Humanetics Innovative Solutions. All rights reserved.

The information in this manual is furnished for informational use only and is subject to change without notice.
Humanetics Innovative Solutions assumes no responsibility or liability for any errors or inaccuracies that may
appear in this manual.

Notice: This product may contain lead

A list of components that may contain lead is being maintained on the Humanetics web site. The list, organized
by dummy type, shows subcomponents that may currently or in the past have contained lead or a lead-based
alloy. Please refer to the Humanetics web site under ATD Lead Disclosure for information regarding lead in this
product. http://www.humaneticsatd.com/Lead_Disclosure

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 2 of 109

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Table of Contents
Table of Contents .............................................................................................................................................. 3

List of Figures ................................................................................................................................................... 6

List of Tables ................................................................................................................................................. 10

Section 1 Introduction .............................................................................................................................. 11

Overview...........................................................................................................................................11

Tools and Recommended Spares ....................................................................................................12

Screw Abbreviations .........................................................................................................................15

Torque Requirements .......................................................................................................................15

Recommended Spares.....................................................................................................................16

Section 2 Instrumentation ........................................................................................................................ 17

Standard 12 Channel instrumentation ..............................................................................................17

Optional instrumentation ..................................................................................................................17

ISO MME Codes ..............................................................................................................................23

Co-ordinate System ............................................................................................................ 26

Signal Polarity, Sensor Function Check .............................................................................. 27

Filter Class .......................................................................................................................... 27

Data Acquisition Options ..................................................................................................................28

Off Board DAS ..................................................................................................................................28

Messring M=BUS On-Board Data Acquisition .................................................................................30

M=BUS description ............................................................................................................. 30

24 Channel M=BUS ............................................................................................................ 33

DTS Onboard SLICE Nano DAS ......................................................................................................35

SLICE 24 Channel Option ................................................................................................... 39

Electrical Interference ......................................................................................................... 39

DTI Hentschel Onboard DAS ...........................................................................................................40

DTI Description.................................................................................................................... 40

KT Micro DAU Onboard DAS ...........................................................................................................42

Micro DAU Description ........................................................................................................ 42

Kyowa 6 Das System .......................................................................................................................45

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Section 3 Disassembly and Assembly ..................................................................................................... 49

Leg Exploded View ...........................................................................................................................49

Leg Disassembly ................................................................................................................. 50

Leg Assembly ...................................................................................................................... 50

Femur Exploded View ......................................................................................................................52

Femur Disassembly ............................................................................................................ 54

Femur (Upper Leg) Assembly ............................................................................................. 55

Femur assembly after static certification ............................................................................. 59

Knee Exploded View ........................................................................................................................60

Knee Disassembly .............................................................................................................. 61

Knee Assembly ................................................................................................................... 62

Assembly After Certification ................................................................................................ 65

Tibia Exploded View .........................................................................................................................66

Tibia Disassembly ............................................................................................................... 68

Tibia Assembly .................................................................................................................... 69

After Calibration .................................................................................................................. 71

Fitting flesh and Covers ...................................................................................................... 72

Flesh Disassembly .............................................................................................................. 75

Section 4 Maintenance ............................................................................................................................ 76

Introduction .......................................................................................................................................76

General External Damage inspection ..............................................................................................76

Support Roller ..................................................................................................................................76

Red Neoprene Suit Covers ..............................................................................................................76

Protective Plastic End Covers (Part 133-5516) ...............................................................................76

Tibia and Femur ...............................................................................................................................77

Assembly Segment Play ..................................................................................................... 77

Buffers between segments .................................................................................................. 77

Shoulder Bolt and Segment Screw Tightness Check ......................................................... 77

Knee .................................................................................................................................................77

Knee Meniscus .................................................................................................................... 77

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Knee spring cables and bone stopper cables ..................................................................... 78

Sensor and Electrical Maintenance ..................................................................................................78

General Electrical Maintenance .......................................................................................... 78

Bone Maintenance .............................................................................................................. 78

String Potentiometer Maintenance ...................................................................................... 78

Section 5 Storage .................................................................................................................................... 80

Section 6 Weight Specification ................................................................................................................ 80

Section 7 Calibration and Certification Testing ........................................................................................ 81

Calibration and Certification Overview .............................................................................................81

Femur and Tibia Bone Assembly Certification .................................................................................82

Introduction.......................................................................................................................... 82

Femur and Tibia assembly Certification .............................................................................. 82

Knee Certification .............................................................................................................................87

Frontone Test Fixture for Static Certification ...................................................................... 89

Section 8 Pendulum Dynamic Certification.............................................................................................. 91

Introduction .......................................................................................................................................91

E-Liner FLEX ZERT ............................................................................................................ 92

Leg Preparation for Pendulum Dynamic Certification ......................................................................93

Pendulum Rig Preparation ...............................................................................................................96

Running a test ..................................................................................................................................97

Data Processing ...............................................................................................................................98

Pendulum Femur Corridors ..............................................................................................................98

Section 9 Dynamic Inverse Certification Test .......................................................................................... 99

Introduction .......................................................................................................................................99

Inverse Test Description...................................................................................................................99

Preparation of the Inverse Test set up ...........................................................................................100

Impactor Friction, Stroke Phases and Speed Measurement .........................................................101

Leg Preparation for Dynamic Inverse Test.....................................................................................102

Running a Dynamic Inverse Test ...................................................................................................102

Data Processing .............................................................................................................................103

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Inverse Femur Corridors ................................................................................................................104

Section 10 Vehicle Test ........................................................................................................................... 105

Introduction .....................................................................................................................................105

Leg Preparation for Car Test ..........................................................................................................105

Injury Thresholds ............................................................................................................................105

Leg Loading limits in free flight .......................................................................................................106

Determination of Impact Speed ......................................................................................................106

Catch Rope ....................................................................................................................................107

Impactor Pusher Plate ....................................................................................................................107

Section 11 Manual Update Log ............................................................................................................... 109

List of Figures
Figure 1 T-Handle Wrenches ..................................................................................................................... 12
Figure 2 Hex Wrenches ..............................................................................................................................12
Figure 3 Ratchet offset wrench with hex bits kit .........................................................................................13
Figure 4 Leg wire setting tool 133-5112 .....................................................................................................13
Figure 5 Knee spacer tool 133-5113 ..........................................................................................................14
Figure 6 Tibia and Femur base tool 133-8129 ................................................................................................14
Figure 7 Optional Instrumentation for Femur ..............................................................................................18
Figure 8 Detail A, Exploded View, upper and lower knee 133-7507 ..........................................................19
Figure 9 Wire routing for Detail An Optional Sensors 133-7507 ................................................................19
Figure 10 Wire routing out of segment for optional sensors Detail A in upper knee ....................................20
Figure 11 Similar arrangement to Detail A, but with 2 Uniaxial Kyowa Accelerometers. Assembly 133-7600
......................................................................................................................................................20
Figure 12 Sensor IES 3103 ARS example location, knee lower. .................................................................21
Figure 13 Kyowa accel 3 axis option for leg top and bottom locations, (mount 133-7530) ..........................21
Figure 14 Optional Instrumentation, for Tibia ..................................................................................................22
Figure 15 Leg Local Sign Convention .............................................................................................................26
Figure 16 Leg manipulations for positive output ...........................................................................................27
Figure 17 Clamping Arrangement and Position for Off board Wires ...............................................................28
Figure 18 Off Board wiring left hand side of impact face ..............................................................................29
Figure 19 Off Board wiring right hand side of impact face ............................................................................29
Figure 20 Wiring Diagram for 12 channel M=BUS .......................................................................................30
Figure 21 M=BUS arrangement in knee 12 channels LH side to impact direction..........................................31

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Figure 22 M=BUS arrangement 12 channels RH side of impact direction ......................................................31
Figure 23 Clamping of M=BUS Disconnect Connector ...................................................................................32
Figure 24 M=BUS Terminator housing installation in upper knee ...................................................................32
Figure 25 Fixing M=BUS Wire to Launcher ..................................................................................................32
Figure 26 Right hand side of knee M=BUS 24 channels, sensors not connected ..........................................33
Figure 27 Top right-hand side of knee M=BUS 24 channels, sensors connected ..........................................33
Figure 28 Bottom right-hand side of knee M=BUS 24 channels, sensors connected .....................................34
Figure 29 Top left-hand side of knee Messring 24 channels sensors connected ...........................................34
Figure 30 Bottom left-hand side of knee M=BUS 24 channels, sensors connected .......................................35
Figure 31 Wiring diagram for 12 channel SLICE .............................................................................................36
Figure 32 Typical 12 channel Slice wiring to knee ..........................................................................................36
Figure 33 SLICE disconnect connector ...........................................................................................................37
Figure 34 LH of leg with knee covers fitted 12 channels. Leg wires are not shown secured..........................37
Figure 35 SLICE Right hand side of knee 12 channels showing connectors .................................................38
Figure 36 Leg with disconnect wire, TDAS interface and power supply .........................................................38
Figure 37 Optional SLICE unit 24 channel option (right side) .........................................................................39
Figure 38 Left side wiring example of 24 channel SLICE ...............................................................................39
Figure 39 DTI DAS left hand side of knee showing Di Mod hubs ...................................................................40
Figure 40 DTI DAS right hand side of knee showing crash recorder on the left and DiMod hub on the right.41
Figure 41 DTI DAS General Overview ............................................................................................................41
Figure 42 Exploded view of knee showing Micro DAU integration ..................................................................42
Figure 43 Showing drawing of Micro DAU part numbers ................................................................................43
Figure 44 Right hand side of impact face, lower covers removed ..................................................................43
Figure 45 Left hand side of impact face, covers fitted .....................................................................................44
Figure 46 Schematic layout of 12 channel Micro DAU ....................................................................................44
Figure 47 Kyowa 12 Channel System Configuration Diagram ........................................................................45
Figure 48 Kyowa Side in 12ch .........................................................................................................................46
Figure 49 Kyowa Rear Side in 12ch ................................................................................................................46
Figure 50 Kyowa Disconnect Connector .........................................................................................................47
Figure 51 Kyowa Front side in 24ch ................................................................................................................48
Figure 52 Kyowa Rear side in 24ch.................................................................................................................48
Figure 53 Leg assembly, Exploded View ........................................................................................................49
Figure 54 Screws to be tightened to 8 Nm non-impact side ...........................................................................51
Figure 55 Femur Assembly, Exploded View ...................................................................................................52
Figure 56 133-8129 base with 133-5514 segment and bone clamps inside ...................................................57
Figure 57 133-8129 base with 133-5514 segment, bone clamps and bone assembly ...................................57

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Figure 58 Fitting and tightening first blue segment .........................................................................................58
Figure 59 Fitting thin bone spacer with captive shim ......................................................................................58
Figure 60 Bone exit cable restraint use cable ties (ties not shown trimmed or tightened) ..............................59
Figure 61 Knee Assembly, Exploded View .....................................................................................................60
Figure 62 Meniscus string pot assembly wire feed .........................................................................................63
Figure 63 Meniscus with all string pots assembled. String pots identified ......................................................63
Figure 64 Meniscus wire clamp .......................................................................................................................64
Figure 65 Attachment plate, crimp wires in tension with spacers ready for knee femur block assembly .......65
Figure 66 Cross wire feed through on knee ....................................................................................................65
Figure 67 Tibia Assembly, Exploded View ......................................................................................................66
Figure 68 Typical shim arrangement with .05 shim inside captive shim .........................................................70
Figure 69 Assembly of last two segments on tibia ..........................................................................................71
Figure 70 Flesh Cover System ........................................................................................................................72
Figure 71 Assembly of first flesh layer ............................................................................................................73
Figure 72 Zipper locations alternating on the sides (schematic cross section) ...............................................73
Figure 73 Assembly of flesh second layer .......................................................................................................74
Figure 74 Rubber flesh assembly Velcro positions .........................................................................................74
Figure 75 Rubber flesh tied on with Velcro .....................................................................................................74
Figure 76 Leg with outer cover fitted ...............................................................................................................75
Figure 77 String potentiometer pull wire length ±1mm ....................................................................................79
Figure 78 Example of fixing Teflon sheet to base plate ..................................................................................82
Figure 79 Bone and knee fixture 133-8120 for static assembly bending test femur shown............................83
Figure 80 Static certification fixture 133-8120 showing knee ..........................................................................84
Figure 81 Bone Assembly Fixture (femur shown under bending) ...................................................................85
Figure 82 Femur assembly certification corridor moment vs. deflection showing typical results ....................86
Figure 83 Tibia assembly certification corridor moment vs. deflection showing a typical result .....................86
Figure 84 Knee Certification Fixture ................................................................................................................88
Figure 85 Figure MCL sensor elongation Upper and lower corridor ...............................................................88
Figure 86 Figure ACL and PCL upper and lower corridors .............................................................................89
Figure 87 Frontone FLEX STATIC ..................................................................................................................90
Figure 88 Diagram of Dynamic Pendulum Fixture ..........................................................................................91
Figure 89 Frontone FLEX ZERT showing pendulum operation ......................................................................92
Figure 90 FLEX ZERT, pendulum arm folded back in inverse condition with control box ..............................93
Figure 91 Check screws with 8 Nm torque ......................................................................................................93
Figure 92 Stop cable clearance adjustment using setting tool ........................................................................94
Figure 93 Recommended method to align knee to remove any twist and shear ............................................94

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Figure 94 Attaching Pendulum Ballast Weight ................................................................................................95
Figure 95 Attaching Pendulum Rig Pivot hinge ...............................................................................................95
Figure 96 ...........................................................................................................................................................96
Figure 97 Examples of release latches ...........................................................................................................96
Figure 98 Diagram of Dynamic Inverse Certification Test set up ..................................................................100
Figure 99 Paper cloth wrapping of honeycomb .............................................................................................101
Figure 100 Launch guide with 15° tilt toward guided impactor ......................................................................103
Figure 101 Optional catch rope bracket 133-5034 ........................................................................................107
Figure 102 Impactor guide width setting 113mm ..........................................................................................107
Figure 103 Humanetics Launch plate Part No 133-8200 (Aluminum and Carbon Fiber) .............................108

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List of Tables
Table 1 Contents of the tool kit provided with the leg on delivery. ..................................................................14
Table 2 Screw abbreviations ...........................................................................................................................15
Table 3 Torque Requirements .........................................................................................................................15
Table 4 Spare Parts List ..................................................................................................................................16
Table 5 12 Channel Instrumentation ...............................................................................................................17
Table 6 Example of Optional Instrumentation Parts List .................................................................................22
Table 7 ISO MME Sensor Code table .............................................................................................................24
Table 8 Wire label codes for all sensors .........................................................................................................25
Table 9 Flex PLI Parts List ..............................................................................................................................50
Table 10 Femur Assembly, Parts List .............................................................................................................54
Table 11 Knee Assembly, Parts List................................................................................................................61
Table 12 Tibia Assembly, Parts List ................................................................................................................67
Table 13 Flex PLI GTR Mass ..........................................................................................................................80
Table 14 FLEX-PLI-GTR certification steps ....................................................................................................81
Table 15 Parts List for static fixture 133-8120 .................................................................................................84
Table 16 Pendulum test regulation corridors, peak values within 200 ms after impact ..................................98
Table 17 Max and min pendulum femur corridors ..........................................................................................98
Table 18 Inverse test regulation corridors, peak values within 50 ms after impact .......................................104
Table 19 Max and min femur inverse corridors .............................................................................................104
Table 20 Threshold values for injury channels ..............................................................................................105

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1.1 Overview

Pedestrian Lower Legform Impactors are used to evaluate pedestrian protection afforded by passenger vehicles
in case of vehicle collision with a pedestrian. The current EEVC WG17 Pedestrian lower legform impactor is
known to have certain limitations regarding the biofidelity and the repeatability of the test results. Therefore,
Japan proposed to use a completely new legform, the so-called Flexible Pedestrian Legform Impactor (FlexPLI).
In the year 2000, the Japan Automobile Manufacturers Association, Inc. (JAMA) and the Japan Automobile
Research Institute (JARI) initiated development of the “Flexible Pedestrian Leg form Impactor”. In 2002, an initial
design was made available, followed by the Flex-GT version in 2006. The FLEX-PLI features biomechanically
based femur, tibia and knee design, with biofidelic bending characteristics. In the knee the ligaments are
represented according to human anthropometry. A Technical Evaluation Group (FLEX-TEG), consisting of
governmental and industrial parties evaluated the possibility to use the leg form impactor for Global Technical
Regulation on Pedestrian Safety (PS-GTR). Humanetics was a member of this group as dummy manufacturer
and was asked to review the GT design and manufacture the leg. This review highlighted a number of
improvements and the proposed GTR design was accepted. The performance of the leg was intended to remain
the same to ensure existing test data was still valid.

The components of the leg consist of a segmented femur with a suspension bracket at the top, a knee consisting
of two aluminium blocks connected together with wires and springs, a segmented tibia as per the femur and a
flesh system of rubber sheet and Neoprene.

The main improvements were centralising the knee ligament deflection sensors to avoid impact direction
sensitivity, balancing the spring force load in the knee joint to reduce knee joint twist about vertical axis, various
improvements related to handling and repeatability, introduction of a full bridge strain gage configuration,
additional optional sensors and incorporating on board Data Acquisition Systems (DAS) to improve free flight
stability.

Humanetics also reviewed the quasi static calibration procedures for internal bones, thigh, knee and lower leg
assemblies. The pendulum dynamic calibration rig and procedure were also updated to provide more realistic
loading. The high-speed inverse linear guided impactor test is also a requirement for the GTR 9 regulation.

The standard leg instrumentation has 12 channels; this includes 3 full bridge strain gage sensors in the thigh and
4 in the lower leg all measuring leg bending moments, an accelerometer and 4 string potentiometers in the knee,
each one measures specific ligament elongation. There are also options for a further 26 linear accelerometer
channels and 9 Angular Rate Sensors (ARS).

Flex GTR has symmetric design so can represent a right or left leg.

The manual structure is as follows: - Tools / Standard Instrumentation / Optional Instrumentation / ISO Codes /
DAS Options / Disassembly and Assembly / Maintenance / Storage / Weight Spec / Calibration and Certification
/ Leg Preparation for Dynamic Testing and Car Test Information.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 11 of 109

Several types of standard tools are used in the assembly and disassembly of the dummy. T-handle wrenches
(Figure 1) and hex wrenches (Figure 2) can be used to access most of the fasteners in the dummy. In some
cases, access to fasteners is easier if a ratchet offset wrench with hex bits is used (Figure 3).

Figure 1 T-Handle Wrenches

Figure 2 Hex Wrenches

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 12 of 109

An 8, 4 mm and 1/8” open ended wrenches are required. A wire spacer tool 133-5112 is needed see Figure 4 to
set bone assembly wire stopper clearance and there is another spacer tool to space the knee string
potentiometer attachment part 133-5113 for knee assembly. See Figure 5. Two of these are used to hold string
potentiometer attachment plate in position on assembly. All these tools along with 133-8129 figure 6, are
provided with the leg as part of the toolbox.

Figure 4 Leg wire setting tool 133-5112

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Figure 6 Tibia and Femur base tool 133-8129

Note: Apart from the string potentiometer #2-56 UNC cap head screws and the ARS optional angular rate
sensors which use #0-80 cap heads all the leg screws are metric.

PART NO. QTY DESCRIPTION

6002565 1 Transport Case
6002558-13 25 meter roll Double Sided Tape, 50mm Wide
5000522 20 M5 Nyloc Nuts
133-5112 1 Wire Setting Tool
5000819 1 Open Ended Wrench, 4mm
9003192 1 Open Ended Wrench, 1/8”
133-5113 2 Setting Tool, Knee
133-5025 10 Double Sided Tape, Impact Segment
133-8129 1 Bone base assembly tool
Table 1 Contents of the tool kit provided with the leg on delivery.

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©2018 Humanetics Innovative Solutions
Note: A strong double-sided tape is used extensively on the Flex leg. Humanetics recommends the use of this
tape or a tape with the same strength to maintain performance.

1.3 Screw Abbreviations

ABBREVIATION DESCRIPTION
SHCS Socket Head Cap Screw
BHCS Button Head Cap Screw
FHCS Flat Head Cap Screw
SHSS Socket Head Shoulder Screw
MSSFP Metric Socket Setscrew Flat Point
Table 2 Screw abbreviations

1.4 Torque Requirements

DESCRIPTION TORQUE Nm
Leg attachment to knee front M8 BHCS 8
Leg attachment to knee rear M8 MSSFP 8
All segment M6 BHCS 3
Shoulder link screws M10 3
Table 3 Torque Requirements

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PART NO QTY DESCRIPTION

133-5165 1 Femur bone assembly tested and certified
133-5365 1 Tibia bone assembly tested and certified
133-5013 1 Cover inner femur
133-5014 1 Cover inner femur
133-5015 1 Cover inner tibia
133-5016 1 Cover outer tibia
133-5017 2 Cover Flex PLI GTR
133-5516 1 End cover
133-5019 6 Velcro bundle tie, 500 mm long
61-503-05-01-00 1 Cable assembly 150 mm STR POT R to 7 pin
male
61-507-05-01-00 1 Cable assembly 150 mm STR POT L to 7 pin
male
61-503-05-01-00-MB 1 Cable assembly 150mm STR POT R to 7 pin
male 3.3 Volt DAS system only
61-507-05-01-00-MB 1 Cable assembly 150mm STR POT L to 7 pin
male 3.3 Volt DAS system only
Table 4 Spare Parts List

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FLEX-PLI-GTR is offered with 12 channel standard instrumentation, measuring tibia and femur bending
moments and knee ligament elongations as well as acceleration in the knee bottom (knee tibia block) in impact
direction. The standard instrumentation channels are listed in Table 5. The channels intended for injury
assessment are the 4 tibia bending moments, knee Medial Collateral Ligament (MCL), Anterior Cruciate
Ligament (ACL) and Posterior Cruciate Ligament (PCL) elongations. These channels are controlled by the
certification procedures given in Sections 8 and 9.

Corridors are also provided for the femur channels. These corridors are not a regulation requirement, they are a
guide to advise on the expected performance of the femur.

The accelerometer can be used for force calculation and the LCL provides information on elongation after
rebound crossover of the knee.

2.2 Optional instrumentation

The FLEX-PLI offers a range of optional instrumentation for research purpose. Examples are using ARS for in
flight stability and accelerometers for local force measurement. When running regulatory tests with optional
instrumentation it is recommended to check that the total mass of the tool, including a certain amount of cable
length, does not exceed the regulatory requirement. Each individual femur and tibia segment can be
instrumented with a uniaxial accelerometer in impact direction. Tri-axial accelerometers and/or angular rate
sensors are also available at various locations. It is recommended that damped accelerometers are used on
FLEX PLI.

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Figure 9 Wire routing for Detail An Optional Sensors 133-7507

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Figure 11 Similar arrangement to Detail A, but with 2 Uniaxial Kyowa Accelerometers. Assembly 133-7600

There is also an alternate mirror image of 133-7600 available 133-7540 and for 133-7507 the mirrored mount is
133-7545 to route wires to the opposite side for DAS connection to prevent wires going around the knee thus
avoiding wire damage and good wire routing.

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Sensor IES 3103 ARS triaxial can be installed in the first segment from knee in the femur and tibia. The sensor
bolts directly to the aluminium segment in each case. The sensor can also be mounted so that the cable can exit
either side. See Figure 12. A special impact cover is required to accommodate the sensor.

Figure 12 Sensor IES 3103 ARS example location, knee lower.

Figure 13 Kyowa accel 3 axis option for leg top and bottom locations, (mount 133-7530)

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ITEM QTY PART NO. DESCRIPTION

1 1 133-7508 ACCEL INSTRUMENTED OPTION LEG TOP & BOTTOM
2 6 133-7514 IMPACT SEGMENT - INSTRUMENTED ASSEMBLY (FEMUR)
2 8 133-7514 IMPACT SEGMENT - INSTRUMENTED ASSEMBLY (TIBIA)
3 1 133-7507 ACCEL & ARS INSTRUMENTED OPTION FOR KNEE
4 1 133-7502 KNEE END ACCEL MOUNT
5 1 133-7516 TAPE, DOUBLE SIDED
6 1 5000164 SCREW, SHCS M2 X 0.4 X 18
7 3 IT-TBD DTS ANGULAR RATE SENSOR
8 6 9003103 SCREW, SHCS #0-80 X 5/16
ACCELEROMETER, LINEAR TRIAXIAL, MEASUREMENT
9 1 MS-68C
SPECIALTIES MS 68C
10 1 133-7506 SPECIAL M2 ACCEL FIXING
Table 6 Example of Optional Instrumentation Parts List

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For the identification of sensor channels and for computer processing of signals the following codes have been
established for ISO MME.

Transd Fine Fine Fine

Location Test Physical Filter
No. Category Position Main Location Location Location Direction
(Description) Object Dimension Class
Location 1 2 3
Femur Moment
1 3 Upper, X standard D 0 FEMR UP 00 PF MO X C
Femur Moment
2 2 Middle, X standard D 0 FEMR MI 00 PF MO X C
Femur Moment
3 1 Lower, X standard D 0 FEMR LO 00 PF MO X C
Knee LCL
4 Elongation standard D 0 KNEE LC 00 PF DS Z C
Knee ACL
5 Elongation standard D 0 KNEE AC 00 PF DS Z C
Knee PCL
6 Elongation standard D 0 KNEE PC 00 PF DS Z C
Knee MCL
7 Elongation standard D 0 KNEE MC 00 PF DS Z C
Tibia Moment
8 1 Upper, X standard D 0 TIBI UP 00 PF MO X C
Tibia Moment
2 Middle
9 Upper, X standard D 0 TIBI MI UP PF MO X C
Tibia Moment
3 Middle
10 Lower, X standard D 0 TIBI MI LO PF MO X C
Tibia Moment
11 4 Lower, X standard D 0 TIBI LO 00 PF MO X C
Knee Bottom
12 Acceleration, Y standard D 0 KNEE BO 00 PF AC Y C
Femur Top
13 Acceleration, X additional D 0 FEMR TP 00 PF AC X C
Femur Top
14 Acceleration, Y additional D 0 FEMR TP 00 PF AC Y C
Femur Top
15 Acceleration, Z additional D 0 FEMR TP 00 PF AC Z C
Femur
Segment 1
16 Acceleration, Y additional D 0 FEMR 01 00 PF AC Y C
Femur
Segment 2
17 Acceleration, Y additional D 0 FEMR 02 00 PF AC Y C
Femur
Segment 3
18 Acceleration, Y additional D 0 FEMR 03 00 PF AC Y C
Femur
Segment 4
19 Acceleration, Y additional D 0 FEMR 04 00 PF AC Y C
Femur
Segment 5
20 Acceleration, Y additional D 0 FEMR 05 00 PF AC Y C
Femur
Segment 6
21 Acceleration, Y additional D 0 FEMR 06 00 PF AC Y C
Knee Upper
22 Acceleration, X additional D 0 KNEE UP 00 PF AC X C

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Transd Fine Fine Fine
Location Test Physical Filter
No. Category Position Main Location Location Location Direction
(Description) Object Dimension Class
Location 1 2 3
Knee Upper
23 Acceleration, Y additional D 0 KNEE UP 00 PF AC Y C
Knee Upper
24 Acceleration, Z additional D 0 KNEE UP 00 PF AC Z C
Knee Upper
Angular Rate,
25 ωX additional D 0 KNEE UP 00 PF AV X C
Knee Upper
Angular Rate,
26 ωY additional D 0 KNEE UP 00 PF AV Y C
Knee Upper
Angular Rate,
27 ωZ additional D 0 KNEE UP 00 PF AV Z C
Knee Lower
28 Acceleration, X additional D 0 KNEE LO 00 PF AC X C
Knee Lower
29 Acceleration, Y additional D 0 KNEE LO 00 PF AC Y C
Knee Lower
30 Acceleration, Z additional D 0 KNEE LO 00 PF AC Z C
Knee Lower
Angular Rate,
31 ωX additional D 0 KNEE LO 00 PF AV X C
Knee Lower
Angular Rate,
32 ωY additional D 0 KNEE LO 00 PF AV Y C
Knee Lower
Angular Rate,
33 ωZ additional D 0 KNEE LO 00 PF AV Z C
Tibia Segment
1 Acceleration,
34 Y additional D 0 TIBI 01 00 PF AC Y C
Tibia Segment
2 Acceleration,
35 Y additional D 0 TIBI 02 00 PF AC Y C
Tibia Segment
3 Acceleration,
36 Y additional D 0 TIBI 03 00 PF AC Y C
Tibia Segment
4 Acceleration,
37 Y additional D 0 TIBI 04 00 PF AC Y C
Tibia Segment
5 Acceleration,
38 Y additional D 0 TIBI 05 00 PF AC Y C
Tibia Segment
6 Acceleration,
39 Y additional D 0 TIBI 06 00 PF AC Y C
Tibia Segment
7 Acceleration,
40 Y additional D 0 TIBI 07 00 PF AC Y C
Tibia Segment
8 Acceleration,
41 Y additional D 0 TIBI 08 00 PF AC Y C
Tibia Bottom
42 Acceleration, X additional D 0 TIBI BO 00 PF AC X C
Tibia Bottom
43 Acceleration, Y additional D 0 TIBI BO 00 PF AC Y C
Tibia Bottom
44 Acceleration, Z additional D 0 TIBI BO 00 PF AC Z C
Table 7 ISO MME Sensor Code table

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TRIAX Sensor
Wire Label
Location (Description) wire label ISOMMECODE
Code
code
Femur Moment 3 Upper, X F3 D0FEMRUP00PFMOXC
Femur Moment 2 Middle, X F2 F1-3 D0FEMRMI00PFMOXC
Femur Moment 1 Lower, X F1 D0FEMRLO00PFMOXC
Knee LCL Elongation LCL D0KNEELC00PFDS0C
Knee ACL Elongation ACL D0KNEEAC00PFDS0C
Knee PCL Elongation PCL D0KNEEPC00PFDS0C
Knee MCL Elongation MCL D0KNEEMC00PFDS0C
Tibia Moment 1 Upper, X T1 D0TIBIUP00PFMOXC
Tibia Moment 2 Middle Upper, X T2 T1-3 D0TIBIMIUPPFMOXC
Tibia Moment 3 Middle Lower, X T3 D0TIBIMILOPFMOXC
Tibia Moment 4 Lower, X T4 D0TIBILO00PFMOXC
Knee Bottom Acceleration, Y AY-KB D0KNEE0000PFACYC
Femur Top Acceleration, X AX-FT D0FEMRTP00PFACXC
Femur Top Acceleration, Y AY-FT A-FT D0FEMRTP00PFACYC
Femur Top Acceleration, Z AZ-FT D0FEMRTP00PFACZC
Femur Segment 1 Acceleration, Y AY-S1 D0FEMR0100PFACYC
Femur Segment 2 Acceleration, Y AY-S2 D0FEMR0200PFACYC
Femur Segment 3 Acceleration, Y AY-S3 D0FEMR0300PFACYC
Femur Segment 4 Acceleration, Y AY-S4 D0FEMR0400PFACYC
Femur Segment 5 Acceleration, Y AY-S5 D0FEMR0500PFACYC
Femur Segment 6 Acceleration, Y AY-S6 D0FEMR0600PFACYC
Knee Upper Acceleration, X AX-KU D0FEMRLO00PFACXC
Knee Upper Acceleration, Y AY-KU A-KU D0FEMRLO00PFACYC
Knee Upper Acceleration, Z AZ-KU D0FEMRLO00PFACZC
Knee Upper Angular Rate, ωX ARX-KU D0FEMRLO00PFAVXC
Knee Upper Angular Rate, ωY ARY-KU AR-KU D0FEMRLO00PFAVYC
Knee Upper Angular Rate, ωZ ARZ-KU D0FEMRLO00PFAVZC
Knee Lower Acceleration, X AX-KL D0TIBIUP00PFACXC
Knee Lower Acceleration, Y AY-KL A-KL D0TIBIUP00PFACYC
Knee Lower Acceleration, Z AZ-KL D0TIBIUP00PFACZC
Knee Lower Angular Rate, ωX ARX-KL D0TIBIUP00PFAVXC
Knee Lower Angular Rate, ωY ARY-KL AR-KL D0TIBIUP00PFAVYC
Knee Lower Angular Rate, ωZ ARZ-KL D0TIBIUP00PFAVZC
Tibia Segment 1 Acceleration, Y AY-S7 D0TIBI0100PFACYC
Tibia Segment 2 Acceleration, Y AY-S8 D0TIBI0200PFACYC
Tibia Segment 3 Acceleration, Y AY-S9 D0TIBI0300PFACYC
Tibia Segment 4 Acceleration, Y AY-S10 D0TIBI0400PFACYC
Tibia Segment 5 Acceleration, Y AY-S11 D0TIBI0500PFACYC
Tibia Segment 6 Acceleration, Y AY-S12 D0TIBI0600PFACYC
Tibia Segment 7 Acceleration, Y AY-S13 D0TIBI0700PFACYC
Tibia Segment 8 Acceleration, Y AY-S14 D0TIBI0800PFACYC
Tibia Bottom Acceleration, X AY-TB D0TIBIBO00PFACXC
Tibia Bottom Acceleration, Y AY-TB A-TB D0TIBIBO00PFACYC
Tibia Bottom Acceleration, Z AZ-TB D0TIBIBO00PFACZC
Table 8 Wire label codes for all sensors

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The recommended local co-ordinate system for standardization follows the SAE J-211 dummy co-ordinate
system.

Figure 15 Leg Local Sign Convention

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The leg can be manipulated manually as shown in Figure 16 below to test polarity and function for positive
output. A spacer can be placed under the leg to assist in the bending of the leg. The positive outputs shown in
Figure 16 below are preferred for standardization; users can use their own polarity if required. For low bending
angles ACL and PCL will be negative when initially manipulated. In the diagram below Figure 16 they are shown
positive. To obtain a positive signal the bend angle would have to be more significant.

For accelerometers signal polarity a blow in the direction of the positive axis should result in a positive
acceleration output (Figure 16). Example: a blow (with a wooden hammer) on the blue impact cover in negative
y-direction should give a negative y-acceleration.

Figure 16 Leg manipulations for positive output

2.3.3 Filter Class

The filter class to be used on the Flex PLI is CFC180 for all channels.

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The FLEX PLI can be used with various options for data acquisition systems. The most basic version is a system
with connection cables to a static laboratory Data Acquisition System (DAS), the so called off-board DAS option.
As the FLEX-PLI is a tool that is in free flight after launch, the off-board cables may affect the free flight
trajectory, accuracy and the cables are susceptible to damage when the tool lands after rebound from the
vehicle. Therefore, the use of off board DAS is not recommended. Currently Humanetics can provide onboard
DAS systems from Messring, DTS SLICE, Hentschel DTI, Kayser-Threde and Kyowa. These systems are
described in paragraphs 2.6, 2.7, 2.8, 2.9 and 2.10. This section is provided in the manual for information only.
For detailed and up to date information on DAS systems, please refer to the original DAS equipment
manufacturer.

2.5 Off Board DAS

For off board DAS umbilical cables of 10m long exit the leg just below the knee. This position is close to the CG
of the leg to minimize the mass affect from the cables in free flight. The cables are clamped to the leg via the top
shoulder link bolts of the tibia to provide restraint protection to the connectors see Figure 17. If off board cables
are not used the clamps should be replaced with washer 133-5105 item 16 in Figure 67. See Figure 18 for left
hand side wiring arrangement. The connectors at the off-board DAS side are specified by the customer and
fitted by Humanetics as all users have different systems.

Figure 17 Clamping Arrangement and Position for Off board Wires

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Most of the wiring for the off-board configuration is in the tibia block. Only the femur bone wire passes over the
knee joint, see Figure 19 for wiring on right hand side.

All the sensors use miniature round connectors with locking latch, either a 7 pin or 16 pin is used.
The 16 pin connectors are for the 3 femur strain gages and for 3 of the 4 tibia strain gages. 16 pin connectors
are also used for optional tri-axial accelerometers.

All the sensor wires are identified to ensure correct connection.

Figure 19 Off Board wiring right hand side of impact face

The leg wires must be balanced to ensure good free flight after launch with 6 channels each side. On the right
side are 2 single channel string pots, 1 single channel accelerometer and 1 three channel wire for the three
femur bone gages. On the left side there are 2 single channel string pots, 1 single channel tibia bone gage and 1
three channel wire for the other tibia bone gages.

It is important to route the off-board cables out of the knee to ensure good free flight to the target. See Figure 17
for an example. Users can establish their own wire routing but the important issues to note are that both sides
are balanced and there is no restriction at release from the pusher plate when fired.

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2.6.1 M=BUS description

An overview of the M=BUS system is shown in Figure 20. The M=BUS is a 6-channel logger fitted inside an
aluminium housing; connection is made to the logger via a plug in PCB board. Each logger has its own battery.
For the standard 12 channels there are two M=BUS units one either side of the knee in the tibia knee block,
three M3 FHCS fix the units to the knee. The sensor connection is made by either a 7 pin or 16 pin miniature
round connector with locking latch. For M=BUS left hand side of leg see Figure 21. For detailed use and
specifications please refer to the supplier’s user instructions.

Figure 20 Wiring Diagram for 12 channel M=BUS

For leg wire routing please refer to Figure 21 below, this is typical for both sides.

The disconnect wire is a blue coax cable, the brass end fitting can be clamped to one of the off-board cable
clamps just below the knee see Figure 22. This direct clamping avoids any damage to the connector. Be careful
not to crush the connector when clamping. Only one cable clamp requires fitting for Messring installation. A hole
also has to be cut in the outer red cover to allow exit of the cable if this exit location is used. Users can also route
the disconnect wire out of the top of the leg to avoid cutting the outer red cover, a longer disconnect wire would
be needed for this.

After the test the disconnect wire is reconnected and data can be downloaded to a PC installed with the
Messring Crashsoft software.

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Inside the femur block there is a terminator housing to complete the coax wiring, see Figure 24, two M3 SHCS
retain the part. The terminator can only be accessed when the knee is disassembled. If the knee is stripped
down for access it is recommended the knee is recertified.

The loggers are programmed to specific sensors for sensitivity, range and software recognition. Loggers cannot
change location and connector labels must match to ensure connection to the sensor.

Figure 21 M=BUS arrangement in knee 12 channels LH side to impact direction

Figure 22 M=BUS arrangement 12 channels RH side of impact direction

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Figure 24 M=BUS Terminator housing installation in upper knee

Figure 25 shows the M=BUS disconnect wire on the launcher and how the coax wire is routed and fixed to the
launcher. The disconnect design has a low release force, however a strong tape is recommended to hold the
wire in place.

Figure 25 Fixing M=BUS Wire to Launcher

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Four, six channel loggers can be fitted to the leg to provide 24 channels of data recording. See figures below for
typical installation. Wire connections can vary according to optional sensors installed.

Figure 26 Right hand side of knee M=BUS 24 channels, sensors not connected

Figure 27 Top right-hand side of knee M=BUS 24 channels, sensors connected

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Figure 29 Top left-hand side of knee Messring 24 channels sensors connected

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2.7 DTS Onboard SLICE Nano DAS

For detailed use and specifications please refer to supplier’s user instructions.

The SLICE is a modular system where a 3-channel bridge SLICE can be stacked onto a base SLICE; in this
case one base SLICE handles 12 channels of data. As the FLEX-PLI has limited space to package the SLICE
stack a mounting board has been designed by DTS to link four bridges together allowing one base SLICE to be
used. The unit is fixed using four M3 pozi head screws. Sensor connection to the DAS is via either 7 or 16 pin
round miniature connectors see Figure 31 & 32 for 12 channel wiring arrangement. After disconnecting the
SLICE is powered by a Super capacitor mounted on the same side of the knee as the standard 12 channel DAS
See Figure 32. The super capacitor is quickly charged when reconnected. The wire disconnect is a round 12 pin
connector hard mounted to the launch guide bracket at the top of the femur see Figure 33. This disconnect
position allows disconnect in the push phase from the launcher to avoid the connector affecting free flight
stability. On reconnect the test data can be downloaded to a PC.

If required there is provision to wire in a tape switch for T=0, a wire is provided for this option out of the super
cap housing.

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Typical Slice wiring to knee with SLICE units, on the right in tibia knee block and super cap on the left in femur
knee block, Figure 32.

Figure 32 Typical 12 channel Slice wiring to knee

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To assemble the SLICE fit the SLICE unit with the higher stack part closest to the knee joint as shown in Figure
32 using four M3 cross head type screws two 25mm and two 20mm long. Then fit the super capacitor with the
disconnect wire pointing downward towards the tibia using four M3 x 16 long screws. All the connectors are
identified so connect like for like, MCL to MCL etc. For the two string pot wires that pass across the knee tie
wrap mounts are provided both sides to anchor the wires, see Figure 35 showing connectors on the right-hand
side of the knee. Route the wires as shown to provide adequate slack in the knee joint to prevent any
disconnection or damage to the wires when the knee flexes. The disconnect bracket is fixed to the launch guide
as shown in Figure 33 using M2.5 screws and the 12 pin connector is mated with the connector coming out of
the bottom of the base SLICE. Most of the wires and connectors are behind the knee covers but the gage wires
coming out of the leg must be properly restrained. There should be two tie wraps fixing the bone gage wires
coming out of each bone (tibia and femur) to the end link where it exits the leg. Before fitting the covers note
there are two covers with three holes, one of these covers part 133-5314 must be fitted over the SLICE unit for
screw head clearance as shown in Figure 34, the other cover 133-5315 is necessary for 24 channel DAS when
two SLICE units are fitted. If 24 channels are not being used this cover can go to any of the other three
locations.

Figure 34 LH of leg with knee covers fitted 12 channels. Leg wires are not shown secured.

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Figure 36 Leg with disconnect wire, TDAS interface and power supply

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To complete the system to 24 channels for optional instrumentation, an additional 12 channel SLICE unit is
packaged on the opposite side to the standard 12 channel units in the upper knee for balance and for access to
upper leg sensors to reduce the number of wires crossing the knee joint. See below. The arrangement of SLICE
bridge units and wiring will vary depending on the optional sensors selected.

Figure 37 Optional SLICE unit 24 channel option (right side)

Figure 38 Left side wiring example of 24 channel SLICE

2.7.2 Electrical Interference

The SLICE system has been designed with protective circuitry for EMI (Electro Magnetic Interference), RFI
(Radio Frequency Interference) and ESD (Electro Static Discharge), up to 8000 V. Since Flex PLI can generate
ESD due to its Nylon covered suit and parts the following best practices should be considered.
1. Use of anti-static spray inside the red skin covers. These sprays work by making it more difficult for
static charge to build up on non-metallic surfaces.

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2. Ground all test fixtures, test articles and even Flex PLI. A ground wire could be a small expendable wire
off board. Although an inconvenience on a wireless device this would be a simple way to prevent ESD
and maintain data quality.
3. Any metal parts with mounted sensors should have good continuity back to the knee blocks where the
DAS is mounted. An earthing kit for 12 or additional channels can be provided.
4. If possible, keep laboratory humidity at a level sufficient to prevent dry conditions as dry conditions
promote static build up.

2.8 DTI Hentschel Onboard DAS

2.8.1 DTI Description

The DTI (Digitized Transducer Interface) DAS consists of three hubs (Figure 39 & 40), a 48 channel Hentschel
data recorder (X3) from type 327.04 and an LED quick release unit (Figure 40). The LED shows the status of the
DAS using numerous color signals, an overview of the status signals can be found in the recorder manual. The
quick release is achieved through a modified Lemosa 2F connector. Depending on the channel configuration
one hub may be removed if not needed.

Figure 39 DTI DAS left hand side of knee showing Di Mod hubs

The hubs contain the DiMods (Digitized Modules) for each of the sensors; each hub is engraved with a letter (A;
B; C). The DiMods store individual sensor data then it is transferred to the recorder at a slower rate to ensure
data quality. The DiMods for the attached sensors are located within the hub, it is therefore imperative that the
correct sensor is connected to the corresponding port. To achieve this both the connector sensor side and the
port have been labeled uniquely. Each hub has 9 ports. 7 x 7 pin and 2 x 16 Pin. The six 7 pin ports that are

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positioned away from the center of the knee are sensor ports, as are the two 16 pins ports. The 7 pin ports that
are closest to the middle of the knee (Nr.7, 16, 25) are for the data recorder bus line.

Figure 40 DTI DAS right hand side of knee showing crash recorder on the left and DiMod hub on the right.

There is no standard configuration for the DTI leg. The configuration of the leg is set by the customer and the
sensors and hubs are configured according to these wishes. The maximum number of channels this system can
theoretically supply is 36; this system is therefore capable of keeping pace with possible future developments of
the Flex PLI. Figure 41 shows a schematic overview of the system set up.

Figure 41 DTI DAS General Overview

The sensors (including the leg bones) require calibration with the DTI DAS as a complete unit. If a sensor is
changed the dimod must be physically reconfigured and calibrated to allow for changes in the sensitivity.

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2.9.1 Micro DAU Description

The Flex PLI leg can be configured to use a KT Micro DAU onboard data acquisition system. This configuration
is a 12-channel system with battery backup and USB communication. The design allows any existing leg to have
a Micro DAU iDummy configuration with minimal additional parts. Micro DAU modules are designed to replace
the knee covers over each of the four knee cavities with three to six channels in each cavity. A lithium battery is
provided for approximately 30 minutes of standalone operation.

Figure 42 Exploded view of knee showing Micro DAU integration

The Micro DAU configured leg requires 5.0v input at 600mA during operation using USB communication through
the standard Kistler Crash Designer software. For detailed operation of the Micro DAU system and Crash
Designer software please refer to Kistler documentation.

The Micro DAU system consists of 4 modules. The battery module (133-5713) contains the battery, charger,
USB hub, the leg power/comm exit cable and communication to the rest of the modules. The battery is
lithium/manganese chemistry and provides power for 30 minutes of operation. Three additional sensor modules
(133-5710, 133-5711 and 133-5712) contain 3 or 6 data acquisition channels. Each module provides connectors
for single channels, such as potentiometers or three channels such as femur or tibia moments. Modules 133-
5711 and 133-5712 also provide power/comm inputs and outputs while module 133-5710 contains only
power/comm inputs.

Modules are designed to be ‘daisy chained’ as shown in Figure 43. The battery module begins the chain, with
each module connected to next module. Module 133-5710 is the last module in the chain. Clearance is provided
under each module for power/comm and sensor cables. The clearance is tight due to space restraints so care
must be taken to assure cables are not overlapping or pinched during assembly.

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The battery module also provides the leg exit cable. This cable is configured with a magnetic breakaway
connector assembly. Magnets are configured such that electrical contact is solidly made while preventing
unwanted misalignment. The connector is specifically designed for easy and safe disconnect to prevent cable,
sensor or data acquisition system damage.

Figure 44 Right hand side of impact face, lower covers removed

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Figure 46 Schematic layout of 12 channel Micro DAU

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Four six channel data logger units can be mounted in Flex-PLI-GTR. Each logger has its own re-useable battery
inside with a run time of three minutes. Sensors are connected to the loggers with either 7 pin or 16 pin small
circular connectors. The Kyowa 6 logger is fixed to the side of Flex-PLI-GTR knee block with three low head
SHCS screws.

Please refer to the Kyowa 6 user’s manual regarding detailed use and specifications.

The standard Kyowa 6 - 12 channel system is shown in Figure 47.

Figure 47 Kyowa 12 Channel System Configuration Diagram

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One logger is installed on the front side of the tibia knee block and the other is on the rear side of the femur knee
block. This configuration is shown in Figures 48 and 49.

Figure 48 Kyowa Side in 12ch

Figure 49 Kyowa Rear Side in 12ch

Sensor information can be set with the installed software (DIS-5A) after installing the loggers into the Flex-PLI-
GTR.

The Kyowa 6 system works with sensor ID and TEDS（meeting IEEE-145.1.4 spec）and it is possible to
shorten the amount of preparation time by using the TEDS. For TEDS programmable chips would need to be
fitted which are not currently fitted as standard.

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The disconnect connector is routed towards the top of the Flex-PLI-GTR as shown in Figure 50.

Figure 50 Kyowa Disconnect Connector

This connector is detached when the Flex impactor is pushed out from a launcher system. The launch guide
angle needs to be set up as described in section 9, shown here in Figure 50.

Data can be downloaded when the system is reconnected through DIS-5A software after the test. The internal
battery in the leg form is simultaneously charged when reconnected.

Front side and rear side of the 24ch standard system with four Kyowa6 units is shown in Figure 51 and 52.

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Figure 52 Kyowa Rear side in 24ch

Please refer to the Kyowa 6 user’s manual regarding its use.

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Figure 53 Leg assembly, Exploded View

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ITEM QTY PART NO. DESCRIPTION
1 1 133-5300 KNEE ASSEMBLY, FLEX PLI
2 1 133-5500 TIBIA ASSEMBLY, FLEX PLI
3 1 133-5100 FEMUR ASSEMBLY, FLEX PLI
4 1 133-5020 BUFFER SHEET ASSEMBLY, LEG (NOT SHOWN)
5 1 133-5013 COVER, INNER, FEMUR (NOT SHOWN)
6 1 133-5014 COVER, OUTER, FEMUR (NOT SHOWN)
7 1 133-5015 COVER, INNER, TIBIA (NOT SHOWN)
8 1 133-5016 COVER, OUTER, TIBIA (NOT SHOWN)
9 1 133-5017 COVER, FLEX PLI GTR (NOT SHOWN)
10 6 133-5019 VELCRO BUNDLE TIE, 500mm LONG (NOT SHOWN)
Table 9 Flex PLI Parts List

3.1.1 Leg Disassembly

When the leg is not being used or shipped the tight-fitting flesh system should always be removed to prevent
stretching and long-term indentation from the leg components.

Remove the four aluminium side covers each held on with 4x M4 FHCS. Disconnect the 1x femur, 2x tibia and
1x accelerometer DAS connectors and any other optional connectors if fitted coming out of the knee assembly.
These connectors are labelled for refitting on assembly.

Loosen the two M8 MSSFP screws from the non-impact side of the leg on each knee block by about three turns
of the screw.

To access the other leg attachment screws in the knee carefully prize away the two blue impact side plastic
covers (if assembled). Use a screwdriver or similar inside one of the blue cover lightening holes and gently lever
away from the double-sided tape attaching it to the knee. Remove the accelerometer if fitted to prevent damage
then remove the 2x M8 BHCS from each knee block. The femur and the tibia can then be pulled out of the knee.

3.1.2 Leg Assembly

Insert the Femur into the knee block femur (133-5320) ensuring it is the correct way around with impact
segments on the impact side. Fit two M8x35, BHCS into the knee block impact side counter bored holes and
tighten see Figure 54. Fit or tighten the two M8x30 set screws at the non-impact side of the leg and screw into
their stops. Carry out the same fitting for the tibia.

All these M8 screws must be tightened to 8 Nm as do the 4x non-impact side M8 set screws in the aluminum leg
segments see Figure 54. Note when tightening the segment screws start with the screw nearest to the knee to
avoid the inner spacer levering over inside the segments.

Reconnect all the sensor connectors to the DAS. For off board or on-board configurations, wires will require
careful routing and securing see section 2.

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Fit the accelerometer to the impact side of the knee tibia block and connect wire to DAS and route the cable
safely. Fit the blue impact covers to the impact side of the knee blocks by carefully aligning them before pressing
down on the double-sided tape that fixes them. If the tape is damaged, folded over or not sticky it should be
replaced. Fit the 4x aluminium side covers with the M4 FHCS be careful wires and connectors are not crushed
and are free to move when the knee is flexed. A loop in the wires should be made for wires crossing the knee
joint. The disconnect wire will either exit at the top of the leg or just below the knee depending on DAS used. If
exiting at the top, make sure wire is tied to links and has sufficient play between ties to allow for the femur to
bend and not pull on the wire.

Figure 54 Screws to be tightened to 8 Nm non-impact side

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Figure 55 Femur Assembly, Exploded View

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ITEM QTY PART NO. DESCRIPTION
1 1 133-5165 FEMUR BONE ASSEMBLY TESTED & CERTIFIED
2 1 133-5508 BONE CLAMP THIN, KNEE
3 1 133-5503 BONE CLAMP THIN, FEMUR/TIBIA
4 1 133-5506 BONE CLAMP THICK, KNEE
5 1 133-5502 BONE CLAMP THICK, FEMUR/TIBIA
6 5 133-5505 SPACER, BONE CONTACT, THICK
7 1 133-5504 SHIM, BONE CLAMP (.4 THICK) OPTIONAL
8 1 133-5510 RUBBER BUFFER, FEMUR/TIBIA END
9 5 133-5507 SPACER, BONE CONTACT, THIN
10 5 133-5509 SHIM (0.4 THICK) OPTIONAL
11 1 133-5514 INNER SEGMENT, KNEE
12 5 133-5534 INNER SEGMENT ASSEMBLY
13 1 133-5535 INNER SEGMENT ASSEMBLY CLOSES TO KNEE
14 28 5000465 SCREW, BHCS M6 X 1 X 18
15 14 133-5515 LINK
16 1 133-5108 SEGMENT TOP, FEMUR
17 1 133-5102 PLATE, TOP
18 1 133-5103 LAUNCH GUIDE
19 4 133-5104 WASHER, 12 ID X 26 OD X 3
20 16 133-5106 SHOULDER BOLT
21 2 5000094 WASHER, FLAT M6 (6.7 ID X 12.5 OD X 1.0 THK.)
22 2 5000604 SCREW, SHCS M6 X 1 X 14
23 1 5000008 SCREW, SHCS M6 X 1 X 30
24 1 133-5107 ROLLER
25 8 133-5521 WASHER, CABLE
26 4 133-5110 CABLE ASSEMBLY, FEMUR
27 4 5000522 HEX NUT, M5 X 0.8 NYLOK
28 1 133-5516 END COVER
29 6 5000072 SCREW, BHCS M6 X 1 X 16
30 4 5000814 SCREW BHCS, M5 X .8 X 8
31 4 5000393 SCREW, SHCS M3 X .5 X 6
32 2 5000769 SCREW, MSSFP M8 X 16
33 6 133-5025 TAPE, IMPACT SEGMENT
34 1 133-5028 TAPE, END COVER, 12 X 24
35 4 133-5027 TAPE, END COVER, 10 X 12
36 2 133-5026 TAPE, END COVER, 12 X 16
37 1 133-5518 COVER, END IMPACT
38 1 133-5519 COVER, END IMPACT, (KNEE END)
39 6 133-5517 IMPACT SEGMENT
40 5 133-5001 SHIM, (T0-5) OPTIONAL (NOT SHOWN)
41 2 133-5002 SHIM, BONE CLAMP (T0-05) OPTIONAL (NOT SHOWN)
42 2 133-5003 SHIM, BONE CLAMP (T0-5) OPTIONAL (NOT SHOWN)
43 2 133-5004 SHIM, BONE CLAMP (T0-6) OPTIONAL (NOT SHOWN)

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ITEM QTY PART NO. DESCRIPTION
44 5 133-5005 SHIM (T0-6) OPTIONAL (NOT SHOWN)
45 15 133-5012 SHIM, (.05) OPTIONAL (NOT SHOWN)
Table 10 Femur Assembly, Parts List

3.2.1 Femur Disassembly

Remove the end cover 133-5516 by removing the four M5 BHCS and launch guide 133-5103 by removing the
two M6 SHCS and washers.

It is advised to lay the parts on the bench in the order and orientation as they are removed so that parts can be
reassembled in the same order. This is not critical but is recommended. When handling the bone core, it is
recommended that gloves are worn to prevent getting splinters in the hand. Do not run your hand along the bone
without protection.

Remove the eight blue impact covers over each segment. These are taped to the segments and located over M6
BHCS so need to be peeled off.

Remove the four stopper wires by unscrewing the M5 Nyloc nuts. Replace the washers and nut on to the cable
once removed to keep them together.

The assembly can be placed in the holding base tool 133-8129 and locked in place. This will stabilise the
assembly and can make disassembly easier. The femur will be dismantled starting from the top part 133-5102.

Remove the four M6 BHCS that hold on the top plate and remove the top plate. A rubber buffer should be
bonded to the inside of the top plate.

Remove the 16 shoulder bolts (133-5106) and 14 links (133-5515).

Remove the 4 M6 BHCS from each side of the top blue segment. Slide the top aluminium segment off the bone,
the inner clamps along with their shims should come out as well as an assembly.

Slide off all the blue segments one by one, be careful not to rock the segment too much when sliding off to avoid
any damage to the strain gages and wires that run down the centre of the bone.

Remove the four M6 BHCS each side of the remaining aluminium segment and loosen the two M8 set screws on
the non-impact side.

Remove the base clamp if fitted (used for stability) then slide the segment off the bottom of the bone. The two
bone clamps will also come off along with any shims. The bone is now free of any parts and can be inspected.
Try and keep all the segments laid out so that all the shimmed spacer bone contact parts are orientated the
same for easier reassembly. The retained shims for bone fit attached in the blue segments can be disassembled
by removing the two M6 BHCS on the non-impact side. Shims for each segment should be kept together.
Removal of both the curved spacer bone contact thick (133-5505) and non-impact side spacer bone contact thin
(133-5507) from the blue segment is not necessary at this stage unless detail inspection of the spacers is
required.

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The double-sided tape can be reused if still sticky and if it is not folded over. It will also be important to check for
any damaged parts that would need replacement, see maintenance section 4.

3.2.2 Femur (Upper Leg) Assembly

Before assembly check all rubber buffers are bonded to segments. In the unlikely event a buffer should become
dislodged, damaged or lost it will need re-bonding. When bonding the segment buffers ensure surfaces of both
parts are prepped before bonding, prepare plastic with 240 grit paper and rubber with 80 grit, degrease then
bond with Loctite 401 or similar.

When handling the bone core, it is recommended that gloves are worn to prevent getting splinters in the hand.
Do not run your hand along the bone without protection.

Start the assembly from the knee end of the bone. The tibia/femur base tool 133-8129 will be required for
assembly as this will allow the bone to be assembled flush with the end clamps, make assembly stable when
building and simplify segment assembly. The part 133-8129 from the bone static fixture can also be used and is
shown in Figure 55.

Fit bone clamp 133-5506 inside the tool base with curved end upwards and groove side inwards, loosely fix with
2x M8 x 20 screws. Fit the inner segment knee 133-5514 over the clamp and attach finger tight with 2x M6 x 16
BHCS. See Figure 56.

Place 133-5508 over the bone PCB curved end up and insert bone and clamp into the base see Figure 56. The
PCB is on the rear of the leg (non-impact side).

Fit 2x M8 x 12 SSFP (Socket Set Flat Point) screw into the fixture base then the 2x M8 x 16 SSFP into 133-5514
segment. Tighten all the screws to 3 Nm.

Lay the PCB exit wire to the side required for the specific DAS wiring requirement. If the knee assembly is to
hand you will be able to check the DAS as to which side this needs to go.

Fit 133-5505 (spacer bone contact thick) to segment 133-5535 (blue segment with rubber buffers both sides)
using 2x M6 x 18 zinc plated BHCS (Button head cap screw). Fit screws diagonally then slide over the bone with
the thick spacer on the impact side. Take care not to damage the black strain gage cover running down the
centre of the bone. The difference in thickness between the rear thin curved spacers and the front impact thick
curved spacers is 0.5mm (12.25 thin and 12.75mm thick). The thinner spacer allows for the shim thickness.

The bone segments should have been laid out in the order they were disassembled, this should help
reassembly, if not the process will still be the same. If the leg has seen a number of tests some wear may have
taken place and a different shim configuration would be required to ensure the bone is rebuilt with as tight a
segment fit as possible. This tight fit allows for wear in future testing and should help keep the leg certified.

Using the previous shim arrangement with its internal flat shims inside the captive shim see Figure 68, locate
against the spacer bone contact thin (133-5507) see Figure 59 and push this assembly centrally into the gap

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against the bone. Note: When fitting the shim assembly use thumb force only, pushing down on the top
of the spacer. Do not hammer shims into place. You should feel high resistance when pushing this assembly
in. You can check the fit by rotating the segment on the bone Z axis. If there is any play remove and add a 0.05
mm (133-5012), 0.1 mm (133-5029) or 0.2 mm (133-5030) flat shim inside the captive shim or any combination
of these to get a tight fit. When the spacer assembly does not fit usually you only need to remove a 0.05 shim
and that will be as tight as you can achieve. When fit is as tight as possible with thumb pressure ensure screw
holes are aligned then fix the shim assembly with 2x M6 x 18 BHCS fitted diagonally and tighten front and rear
screws to 3 Nm. Use the set screw key if needed to align the holes if not aligned by inserting into the hole and
levering the inner assembly into position.

For the next segment assembly attach a spacer bone contact thick to the blue segment part 133-5534 using 2x
M6 x 18 zinc plated BHCS fitted diagonally as per the previous segment. Slide over the bone with rubber buffers
on top side and spacer to the front impact side. Try fitting the same rear shim arrangement as the previous shim
assembly. Adjust shims if still loose; remove a 0.05 shim if the assembly cannot be pushed into the segment.
Align holes to the segment and fit the two rear M6 x 18 BHCS diagonally and torque all 4x M6 screws front and
rear to 3 Nm.

Repeat for the next 3 segments.

For the last 2 segments fit 133-5502 (Bone clamp thick) to the last blue segment and to 133-5108 (Segment top
femur) using 2x M6 x 18 BHCS for the blue segment and 2x M6 x 16 for the top aluminium segment.
Replace the previous large shim (shim bone clamp) that went over the clamp 133-5503 (Bone clamp thin) and fix
into the aluminium segment 133-5108 using 2x M6 x 16 BHCS. Also fit the 2x M6 x 18 BHCS through the back
of the blue segment and tighten. Slide or push these two segments over the top of the bone. If the fit is loose,
over either of the segments add more 0.05 shims until the fit is tight. A higher push force will probably be needed
for this fit as the inner dimension of the two segments may not be perfectly identical, placing the leg on the
ground with assembly base part 133-8129 push down with two hands on the two segments. Once the fit is tight,
tighten all the screws to 3 Nm. Check the distance between the top of the bone and the top of the aluminium
segment. This should be between 1.5 and 2 mm and should match the small rubber buffer glued to the
underside of the stainless-steel top plate. This buffer removes any end play on the bone. On initial assembly this
buffer may have been padded out to prevent bone end play. It is important no end play is present. Fit the top
plate with 4x M6 x 18 BHCS.

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Figure 57 133-8129 base with 133-5514 segment, bone clamps and bone assembly

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 57 of 109

Pass the connector through a side link 133-5515 and fit all the links starting from the knee end and 4x end
washers using the aluminium shoulder bolts as shown on assembly Figure 60 both sides. The segments may
need adjusting slightly to fit the shoulder bolts. Torque all shoulder bolts to 3 Nm. Note some links will need to be
removed later for static certification. Starting from the knee end with the links should pull segments to correct leg
length and avoid further adjustment.

Figure 59 Fitting thin bone spacer with captive shim

To fit stopper cables, first remove the assembly tool part 133-8129. Place washer (133-5521) over each of the
four stainless steel cables (133-5110) and from the knee end, feed through the corner holes in the leg segments.
Place washer (133-5521) over threaded fitting and fit four M5 Nyloc nuts. Set the gap between nut and washer

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to 9.1mm. Check with spacer tool 133-5112. Humanetics recommends the Nyloc nuts should only be used twice
after first removal. If the double-sided tape is not already fitted degrease all the front segments and fit the 6x
double sided tape profiles (133-5025) to the plastic segments, then fit all the impact segments (133-5517)
locating over two BHCS. When handling the bone assembly try to avoid touching the tape when it is exposed,
this will help extend its life. It the tape loses its stickiness or gets folded over replace with new.

Fit the 4x M3 x 8 SHCS if not already fitted to the front of the two end aluminium end segments. Degrease the
front of the segments and fit the small double-sided tape parts if not already fitted as shown in exploded view
Figure 55. Fit the two-end impact covers 133-5518 and 133-5519.

Where the bone wire comes out through the link, tie on two cable ties one on the link and one on wire attached
to each other as shown in Figure 60 to provide restraint to the wire. The femur must be certified before full leg
assembly. Remove the base 133-8129 if not being directly calibrated after build.

Note: a few of the links, washers and shoulder screws will need to be removed and replaced to fit onto the static
certification fixture 133-8120. Keep parts together ready for final assembly.

Figure 60 Bone exit cable restraint use cable ties (ties not shown trimmed or tightened)

3.2.3 Femur assembly after static certification

Fit removed links and shoulder bolts. After pendulum test fit launch guide and roller as shown in exploded view
Figure 55. Fit end cover (133-5516) with 4x M5 x 8 screws. Also fit any optional sensors and mounts if not
already fitted.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 59 of 109

Figure 61 Knee Assembly, Exploded View

ITEM QTY PART NO. DESCRIPTION

1 1 133-5330 KNEE BLOCK, TIBIA, FLEX PLI
2 1 133-5313 MENISCUS ASSEMBLY
3 4 5000774 SCREW, SHCS M5 X .8 X 10, LOWHEAD
4 1 133-5320 KNEE BLOCK, FEMUR
5 1 133-5302 ATTACHMENT PLATE, STRING POT
6 8 9003159 SPRING, 12 X 40
7 16 9003158 SPRING, 18 X 80

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ITEM QTY PART NO. DESCRIPTION
8 8 133-5310 SPRING CAP, FEMUR
9 8 133-5311 CABLE WASHER
10 8 133-5350 CABLE ASSEMBLY, KNEE ML
11 2 5000203 SCREW, FHCS M3 X 0.5 X 10
12 1 133-5315 COVER, KNEE, FEMUR RIGHT SIDE
13 2 133-5306 COVER, KNEE
14 1 133-5314 COVER, KNEE, TIBIA LEFT SIDE
15 16 5000844 SCREW, FHCS M4 X 0.7 X 8, ZINC
16 4 133-5360 AP CABLE ASSEMBLY
17 12 5000522 HEX NUT, M5 X 0.8 NYLOK
18 4 5000770 SCREW, MSSFP M8 X 30
19 4 5000850 SCREW, BHCS M8 X 1.25 X 35, ZINC
20 4 133-5018 TAPE, FRONT COVER
21 1 133-5304 COVER, UPPER KNEE, FLEX PLI
22 1 133-5305 COVER, LOWER KNEE, FLEX PLI
23 8 133-5318 SPRING CAP, TIBIA
2 61-503-05-01-00 STRING POTENTIOMETER RH (NOT SHOWN)
2 61-507-05-01-00 STRING POTENTIOMETER LH (NOT SHOWN)
Table 11 Knee Assembly, Parts List

3.3.1 Knee Disassembly

Remove the four aluminum side covers retained with M4 FHCS. Remove the two front blue plastic covers if
these have not already been removed. The blue plastic covers are prized off the knee blocks by inserting a
screwdriver or similar into one of the holes and gently levering away from the strong double-sided tape that fixes
them.

Take off the accelerometer if not already removed then remove the 8 large springs (4 each end) by unscrewing
the eight M5 Nyloc nuts on the stainless-steel wires. Hold the wire on its end with an1/8” open ended wrench to
allow this. Remove the washers. Lay the knee on its side and pull out the eight wires and springs. Replace the
washers on the wire to keep them together.

Before removing the small cross ligament springs the attachment plate holding the string pot wires must be
unscrewed otherwise string pots would be damaged when the two knee blocks are pulled apart. Remove the two
M3 flat head screws fixing the attachment plate 133-5302 to the femur block.

Now unscrew the four M5 Nyloc nuts holding the central cross wires and remove the four washers and smaller
springs from the tibia block.

Lift the femur block away from the tibia block. The fitting on the end of these wires can catch on the hole in the
counter bore so the cables may require some realignment to free them.

Remove the wires and smaller springs from the femur block.

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On the tibia block disconnect the crimped ends of the spring pots from the attachment plate and remove
attachment plate.

To remove the meniscus for access to spring pots remove the four M5 low head cap screws and pull it away
from the tibia block. These screws should have been thread locked in so may be stiff. If the string pots need
servicing remove wire retaining clamps and unscrew the #2-56 cap screws fixing the pots.

Take note to check there has been no slippage on the crimps on the string pot mechanical wires. The left hand
and right hand pull wires should both be 61.5 mm from the stop at the potentiometer to the start of the ball fitting
see Figure 77.

3.3.2 Knee Assembly

Make a note of the string pot serial numbers and their ligament positions; this is needed for DAS identification for
sensitivity input. Also see paragraph 4.8.3 for string pot check. If pots are due or close to their due date they
should be recalibrated.

Referring to Meniscus assembly (133-5313) feed the connector of one of the right-hand (RH) pull string pots
(part number 61-503-05-01-00) through the inner side of one of the central holes, see Figure 62. The RH and the
LH string pots can be identified from the serial number; the RH has an R at the end of the number and the LH an
L. The two RH pull string pots are positioned closest to the main flange of the meniscus, one is shown fitted in
Figure 62. Attach the string pot with the #2-56 x ¼ long cap head screws making sure the pull wire is directed
towards the furthest away outer bronze bush. Fit the other RH pull string pot in the same way on the opposite
side. Pass the pull wires through their designated bushes see Figure 63. Carry out the same procedure with the
Left hand pull string pots (part number 61-507-05-01-00), the pull wires are directly in line with the two inner
bushes. Feed the pull wires through the bushes. Make sure electrical wires are inside the cavity as much as
possible then run cables through channels both sides and clamp with retaining plate see Figure 64. Fit
assembly to knee block bottom ensuring pot wires are in their grooves. The threads of the four M5x10 low head
cap screws used to retain the meniscus will need to have low strength thread lock applied. This will prevent the
screws coming lose when in service.

If the Messring on board DAS system is to be installed a terminator has to be fitted at this stage.

For details of onboard DAS installation see Section 2.

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Figure 63 Meniscus with all string pots assembled. String pots identified

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 63 of 109

Pass all four ball crimps through attachment plate (133-5302) and place two spacers below it, the pot wires will
then be in tension see Figure 65. Two tubular plastic spacers are shown in the photo to show setup clearly, there
are special spacers in the tool kit for this purpose 133-5113 see Figure 5.

Place four of the smaller Ø12 x 40 springs (9003159) into the knee block femur and place washer (133-5311) on
top of springs; insert wires (133-5360) through springs. Lower this block assembly carefully over the tibia knee
block guiding the wires across to their designated holes and locating over the attachment plate see Figure 66.
Double check the knee femur block is the right way around, ref exploded view Figure 61, and the wires are in
their correct aligned holes and not crossed over. Carefully turn the whole assembly over and locate the
remaining Ø12 springs over the wires. Fit all four washers and Nyloc nuts; tighten nuts down until the washers
are exactly flush with the Femur block. Two wrenches 8mm and 1/8” are required to tighten nuts. Humanetics
recommends that the Nyloc nuts are only used twice after first disassembly, after that new nuts should be fitted.
Fix the attachment plate with 2x M3x8 countersunk screws and remove the spacer blocks. It may be necessary
to remove a spacer block to access the screw. Place eight Ø18 springs into the femur block counter bores and
place washer (133-5310) on top, feed through the 8 wires (133-5350).Turn knee over and fit remaining 8 springs
into their counter bores, fit washers (133-5318) and M5 Nyloc nuts, tighten until all washers are flush with Tibia
block. This can be checked with a flat edge. As a double check the spring protrusion on the Femur block should
be 3mm. In this condition the knee is now ready for certification. Keep remaining parts together for final
assembly.

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Figure 65 Attachment plate, crimp wires in tension with spacers ready for knee femur block assembly

Figure 66 Cross wire feed through on knee

3.3.3 Assembly After Certification

The remaining parts are fitted at the final leg assembly stage see 3.1.2. These are the single channel
accelerometer to impact side of tibia block, the front tape, blue impact covers and the side covers.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 65 of 109

Figure 67 Tibia Assembly, Exploded View

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ITEM QTY PART NO. DESCRIPTION
1 1 133-5565 TIBIA BONE ASSEMBLY TESTED & CERTIFIED
2 1 133-5502 BONE CLAMP THICK, FEMUR/TIBIA
3 1 133-5503 BONE CLAMP THIN, FEMUR/TIBIA
4 1 133-5504 SHIM, BONE CLAMP (.4 THICK)
5 7 133-5505 SPACER, BONE CONTACT, THICK
6 1 133-5506 BONE CLAMP THICK, KNEE
7 7 133-5507 SPACER, BONE CONTACT, THIN
8 1 133-5508 BONE CLAMP THIN, KNEE
9 7 133-5509 SHIM (0.4 THICK)
10 1 133-5510 RUBBER BUFFER, FEMUR/TIBIA END
11 1 133-5511 SEGMENT BOTTOM, TIBIA
12 7 133-5534 INNER SEGMENT ASSEMBLY
13 1 133-5535 INNER SEGMENT ASSEMBLY CLOSES TO KNEE
14 1 133-5514 INNER SEGMENT, KNEE
15 18 133-5515 LINK
16 4 133-5104 WASHER, 12 ID X 26 OD X 3
17 20 133-5106 SHOULDER BOLT
18 8 133-5521 WASHER, CABLE
19 4 133-5530 CABLE ASSEMBLY, TIBIA
20 32 5000465 SCREW, BHCS M6 X 1 X 18
21 4 5000522 HEX NUT, M5 X 0.8 NYLOK
22 1 133-5516 END COVER
23 4 5000814 SCREW, BHCS M5 X 0.8 X 8
24 4 5000393 SCREW, SHCS M3 X .5 X 6
25 2 5000769 SCREW, MSSFP M8 X 16
26 8 133-5025 TAPE, IMPACT SEGMENT
27 1 133-5028 TAPE, END COVER, 12 X 24
28 4 133-5027 TAPE, END COVER, 10 X 12
29 2 133-5026 TAPE, END COVER, 12 X 16
30 1 133-5519 COVER, END IMPACT, (KNEE END)
31 8 133-5517 IMPACT SEGMENT
32 1 133-5518 COVER, END IMPACT
33 7 133-5001 SHIM, (T0-5) OPTIONAL (NOT SHOWN)
34 2 133-5002 SHIM, BONE CLAMP (T0-05) OPTIONAL (NOT SHOWN)
35 2 133-5003 SHIM, BONE CLAMP (T0-5) OPTIONAL (NOT SHOWN)
36 2 133-5004 SHIM, BONE CLAMP (T0-6) OPTIONAL (NOT SHOWN)
37 7 133-5005 SHIM (T0-6) OPTIONAL (NOT SHOWN)
38 21 133-5012 SHIM, .05 (OPTIONAL) (NOT SHOWN)
39 6 5000072 SCREW, BHCS M6 X 16
40 2 133-5522 WIRE EXIT BASE
41 2 133-5523 WIRE EXIT CLAMP
42 2 5000654 SCREW, BHCS M5 X .8 X 12
Table 12 Tibia Assembly, Parts List

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 67 of 109

Remove the end cover 133-5516 by removing the four M5 BHCS.

Remove the 10 blue impact covers over each segment. These are taped to the segments and located over M6
BHCS so will need to be peeled off.

Remove the four stopper wires by unscrewing the M5 Nyloc nuts. Replace the washers and nut on to the cable
once removed to keep them together.

The assembly can be placed upside down in the holding base tool 133-8129 and locked in place. This will
stabilise the assembly and can make disassembly easier. The tibia will be dismantled starting from the bottom
part 133-5511.

Remove the 20 shoulder bolts (133-5106) and 18 links (133-5515).

Remove the four M6 BHCS from both sides of the top aluminium part, segment bottom tibia 133-5511 if the base
clamp is fitted and the four BHCS from the next blue segment pull off the aluminium segment. There should be a
rubber buffer bonded to the inside of this part. There may be additional packing, please maintain this packing if
fitted as it would prevent any end play on the bone. The two bone clamps 133-5502 and 133-5503 and shims
may pull off as well as the next blue segment, it will not pull these clamps and shims out along with the first blue
segment.

Slide off all the blue segments one by one, be careful not to rock the segment too much when sliding off to avoid
any damage to the strain gages and wires that run down the centre of the bone.
Remove the two M6 BHCS on the impact side of the remaining aluminium segment and loosen the two M8 set
screws on the non-impact side.

Remove the base clamp if fitted for (used for stability) then slide the segment off the bottom of the bone. The two
bone clamps will also come off along with any shims. The bone is now free of any parts and can be inspected.
Try and keep all the segments laid out so that all the shimmed spacer bone contact parts are orientated the
same for easier reassembly. The retained shims for bone fit attached in the blue segments can be disassembled
by removing the two M6 BHCS on the non-impact side. Shims for each segment should be kept together.
Removal of both the curved spacer bone contact thick (133-5505) and non-impact side spacer bone contact thin
(133-5507) from the blue segment is not necessary at this stage unless detail inspection of the spacers is
required.

The double-sided tape can be reused if still sticky and if it is not folded over. It will also be important to check for
any damaged parts that would need replacement, see maintenance section 4.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 68 of 109

Before assembly check all rubber buffers are bonded to segments. If for any reason a buffer should become
dislodged, lost or damaged it will need replacing or re-bonding. When bonding the buffer ensure surfaces of both
parts are prepared before bonding, prepare plastic with 240 grit paper and rubber with 80 grit, degrease then
bond with super glue or similar.

When handling the bone core, it is recommended that gloves are worn to prevent getting splinters in the hand.
Do not run your hand along the bone without protection.

Start the assembly from the knee end of the bone. The tibia/femur base tool will be required for assembly as this
will allow the bone to be assembled flush with the end clamps, make assembly stable when building and simplify
segment assembly. The part 133-8129 from the bone static fixture can also be used and is shown in Figure 56.

Fit bone clamp thick 133-5506 inside the tool base with curved end upwards and groove side inwards, Fix finger
tight with 2x M8 x 20 screws. Fit the inner segment knee 133-5514 over the clamp and attach finger tight with 2x
M6 x 16 BHCS.

Place bone clamp thin 133-5508 over the bone PCB and insert bone and clamp together into the base see
Figure 56. The PCB is on the rear of the leg (non-impact side).

Fit 2x M8 x 12 SSFP (Socket Set Flat Point) screws into the tool base then the 2x M8 x 16 SSFP into 133-5514
segment. Tighten all the screws to 3 Nm.

Lay the PCB exit wire to the side required for the specific DAS wiring requirement. If the knee assembly is to
hand you will be able to check the DAS as to which side this needs to go.

Fit 133-5505 (spacer bone contact thick) to segment 133-5535 (blue segment with rubber buffers both sides)
using 2x M6 x 18 zinc plated BHCS. Fit screws diagonally then slide over the bone with the thick spacer on the
impact side. Take care not to damage the black strain gage cover running down the centre of the bone. The
difference in thickness between the rear thin curved spacers and the front impact thick curved spacers is 0.5mm
(12.25 thin and 12.75mm thick). The thinner spacer allows for the shim thickness.
The bone segments should have been laid out in the order they were disassembled, this should help
reassembly, if not the process will still be the same. If the leg has seen a number of tests some wear may have
taken place and a different shim configuration would be required to ensure the bone is rebuilt with as tight a
segment fit as possible. This tight fit allows for wear in future testing and will help keep the leg certified.

Using the previous shim arrangement with its internal flat shims inside the captive shim, see figure 68, locate
against the spacer bone contact thin (133-5507) see Figure 59 and push this assembly centrally into the gap
against the bone. When fitting the shim assembly use thumb force only, pushing down on the top of the
spacer. Do not hammer shims into place. You should feel high resistance when pushing this assembly in. You
can check the fit by rotating the segment on the bone Z axis. If there is play remove and add a 0.05 mm (133-
5012), 0.1 mm (133-5029) or 0.2 mm (133-5030) flat shims inside the inner captive area or any combination of
these to get a tight fit. When the spacer assembly does not fit usually you only need to remove a 0.05 shim and
that will be as tight as you can achieve. When fit is as tight as possible with thumb pressure ensure screw holes
are aligned then fix the shim assembly in the segment with 2x M6 x 18 BHCS fitted diagonally and tighten front

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and rear screws to 3 Nm. You can use the Allan key to align the holes if not aligned by inserting into the hole
and levering the inner assembly into position.

For the next segment assembly attach a spacer bone contact thick to the blue segment part 133-5534 using 2x
M6 x 18 zinc plated BHCS fitted diagonally as per the previous segment. Slide over the bone, rubber buffers on
top side and spacer to the front impact side. Try fitting the same new shim arrangement as the previous shim
assembly. Adjust shims if still loose; remove a 0.05 shim if the assembly cannot be pushed into the segment.
Align holes to the segment and fit the two rear M6 x 18 BHCS diagonally and torque all 4 M6 screws front and
rear to 3 Nm.

Repeat for the next 5 segments.

Check inside 133-5511 (Segment bottom tibia) that the rubber buffer is still bonded inside the bottom of the part.
If not, this will need to be located and re-bonded to prevent bone end play. There may also be additional packing
to prevent the bone moving, this must be replaced.

For the last 2 segments fit 133-5502 (Bone clamp thick) to the last blue segment and to 133-5511 (Segment
bottom tibia) using 2x M6 x 18 BHCS for the blue segment and 2x M6 x 16 BHCS for the aluminium segment.
Ensure the bone clamp thick is on the impact side.

Replace the previous large shim (shim bone clamp) and any other thinner shims that went over the clamp 133-
5503 (Bone clamp thin) and place this assembly inside the two segment assembly, fix to the aluminium segment
using 2x M6 x 16 BHCS and 2x M6 x 18 BHCS to the blue segment. See Figure 69. Slide or push these two
segments over the top of the bone. Check there is no gap between the bone and the rubber buffer by looking
through the holes in the side of the end aluminium segment. If there is this should be packed so that there is no
bone end play. If the fit is loose over either of the segments add a 0.05 shim until the fit is tight on both
segments. A higher push force will probably be needed for this fit as the inner dimension of the two segments
may not be identical, placing the leg on the ground with assembly base 133-8129 and pushing with two hands
down on the two segments. Once fit is tight, tighten all eight screws to 3 Nm.

Figure 68 Typical shim arrangement with .05 shim inside captive shim

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Pass the connector through a link 133-5515 then assemble all the links and washers from the knee end with
shoulder screws as shown in exploded view both sides. The segments may need adjusting slightly to align holes
for shoulder bolts. If off board DAS is being used fit the wire clamps as required (133-5522 & 133-5523) under
the shoulder bolts closest to the knee see Figure 17. The two washers (133-5104) will have to be removed to fit
these clamps. The wire clamps are only used for off board wires or to restrain or guide wires if required.

To fit stopper cables, first remove the assembly fixture part number 133-8129. Place washer 133-5521 over each
stainless-steel cable 133-5530 and feed through the 4 corner holes in all the leg segments from the knee end.
Place another 133-5521 washer over threaded fitting end and fit four M5 Nyloc nuts. Set the gap between nut
and washer to 10.3 mm using 4 and 8mm wrenches. Check gap with spacer tool 133-5112. If the Nyloc nuts are
removed Humanetics recommends they are only used twice.

Figure 69 Assembly of last two segments on tibia

If fitting new double-sided tape, unpeel cover material from the tape on one side (133-5025) and fit over each
segment as shown in exploded view Figure 67. Fit an impact segment (133-5517) locating over two BHCS and
press down onto the tape. Reusing existing tape on segments is OK as long as the tape is flat and still very
sticky.

Where the bone wire comes out through the link, tightly tie on two cable ties as shown in Figure 60 to provide
restraint to the wire. The assembly is now ready for calibration.

Note: When recalibrating a few of the links, washers and shoulder screws will need to be removed and replaced
to allow fitting to the calibration fixture. Keep all parts together ready for final assembly.

3.4.3 After Calibration

Fit removed links and side shoulder bolts. The end cover (133-5516) should be fitted after pendulum calibration
with M5 button head cap screws. Also fit any optional instrumentation.

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On the day of the test or for certification the flesh covers are fitted over the leg. To simplify the fitting of the flesh
system all the covers should be laid on the bench in reverse order of assembly.

Figure 70 Flesh Cover System

N3: Neoprene outer cover

N2: Neoprene second layer (F = Femur, T = Tibia)
N1: Neoprene first layer (F = Femur, T = Tibia)
R2: Rubber inner layers
R1: Rubber outer layers

Step 1: Place the large outer cover (N3) on the bench with lettering face down. Lay 6 strips of Velcro tape over
with fluffy side down, then place the rubber buffer sheet assembly 133-5020 over the strips. (2x R1 and R2). The
large rubber part goes to the top of the leg; this is the opposite end to where the zipper on the outer cover starts.
Adjust the tape so that all the Velcro strips line up with the six markers on the rubber see Figure 74. Lay Thigh 2
and Leg 2 covers (N2F, N2T) over, with the two-knee end inside arrows pointing towards each other allowing a
gap for the knee area then do the same with Thigh 1 and leg 1 covers (N1F, N1T).

Step 2: Place the leg assembly onto the laid-out flesh covers with thigh (femur) section over thigh covers and leg
(tibia) over leg covers with the leg assembly on its side.

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The following positions of the rubber and Neoprene sheets shall be ensured.
• The lower edge of the rubber sheets R1 and the femur Neoprene sheets (N1F, N2F) shall align with the
upper end of the femur knee block
• The recess of the rubber part R2 shall align with the upper end of the femur knee block
• The upper edge of the tibia Neoprene sheets (N1T, N2T) shall align with the lower end of the tibia knee
block
• The outer cover N3 shall be centered to the leg assembly without hanger or ballast weight

Step 3: Fit the black plastic protective end covers to the ends of the leg with 4x M5 BHCS for inverse and car
testing.

Figure 71 Assembly of first flesh layer

Figure 72 Zipper locations alternating on the sides (schematic cross section)

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Step 4: Do up the zippers on Thigh 1 and Leg 1 making sure each zipper is positioned on the side of the leg, in
the area of the shoulder bolts.

Step 5: Turn the leg over and do up the Thigh 2 and Leg 2 zippers making sure these zippers are on the
opposite side to the first. No zipper should be at the back or the front of the leg or it will interfere with the flat
surface of the launcher plate or sustain damage due the impact.

Figure 73 Assembly of flesh second layer

Step 6: Wrap the rubber buffer assembly tightly around the leg using the six Velcro straps. The thick wider part
of the rubber system fits just above the top of the femur knee block. See Figure 75, there are markers on the
rubber showing the exact position for the Velcro. It is important that the fluffy side of the Velcro is to the outside
otherwise the outer cover cannot be stretched over due to grip from the eye side of the Velcro. To get a tight fit
with the Velcro it is easier to get someone to pull the rubber sheet around the leg while you are locking the
Velcro.

Figure 74 Rubber flesh assembly Velcro positions

Figure 75 Rubber flesh tied on with Velcro

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Step 7: Finally pass any off board or disconnect wires through any holes in the outer cover if applicable. For
pendulum testing allow for the electrical wires to exit at the top of the pivot hinge at the top of the upside-down
leg. For inverse and car testing check all wires are correctly positioned and restrained to avoid damage or
disconnect.

Step 8: Wrap the outer cover around the leg. The outer cover is zipped up from the bottom of the leg to make
zipper fitting easier. Some DAS systems have a disconnect wire just below the knee, if that position is used it
may be necessary to cut a hole for this wire. Once the zipper is completely zipped up put the zipper Velcro tag
over to protect zipper and to prevent zipper coming undone.

Figure 76 Leg with outer cover fitted

3.4.5 Flesh Disassembly

Unzip and remove outer cover, remove Velcro straps, unzip and remove second and first bone covers.

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If the leg is passing pendulum or inverse tests that is the main indicator that the leg is suitable to continue
testing. If the leg is not passing, this would indicate wear or damage has taken place and the problem needs to
be investigated and corrected. Obviously, your first indication of problems would appear with unexpected output
of the leg after a vehicle test. Severely exceeding injury criteria may also be a first indication of overloading and
would indicate further inspection is necessary. This section aims to give a systematic checking procedure and
guidance on when parts require inspection, adjustment, replacement, reassembly or recalibration.

The external visual inspections listed below should be carried out at a minimum after every 10 vehicle tests. The
internal inspections should be carried out during every disassembly e.g. when a part has been replaced, during
bone re-shimming, during recalibration of sensors or when investigating an internal problem. If the femur, knee
or tibia assemblies have been reassembled it is recommended that static certification should be carried out
along with, as a minimum, a pendulum certification to ensure the leg is functioning correctly.

4.2 General External Damage inspection

If any parts should become cracked or worn, they should be replaced. Examples would be front impact
segments or worn side link holes or shoulder screws where the links become very lose.
Double sided tape is used in a number of areas. This can be reused if still sticky and not folded over; otherwise it
should always be replaced. All rubber bumpers and rubber flesh sheets should be free of damage.

4.3 Support Roller

Check the blue polymer roller in the top support U bracket at the top of the femur that it is not damaged or worn.

4.4 Red Neoprene Suit Covers

The suit covers, particularly the outer cover is prone to damage as it is the soft contact surface to the vehicle
bumper. Small cuts and tears are not a problem, but large tears or zipper damage will require replacement. The
zipper maintains the tight fit of the covers and this fit should be maintained.
If the leg is not in use or being transported the covers must always be removed as they will become stretched
and indented internally by the leg parts

4.5 Protective Plastic End Covers (Part 133-5516)

These are to protect the ends of the leg when it makes contact with the ground on rebound. These should be
durable now metal inserts have been molded into the part. It is advised to take precautions against severe
continuous ground impact, for instance by the use of catch ropes or cushioning of the test surroundings. If the
leg is likely to be rebounding on the ground after impact, the end covers should be fitted otherwise damage will

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occur to the end aluminum segments of the leg. The end covers should be replaced if they can no longer be
fitted due to damage. (For details on catch rope bracket refer to section 10, vehicle test).

4.6 Tibia and Femur

4.6.1 Assembly Segment Play

With use, the bone segments will become lose due to small indentations to the bone and light wear to the curved
magnesium interfaces with the bone. If there is concern with the amount of play the tibia or femur assembly
should be re-shimmed and statically recertified. See section 7.2. The tibia and femur segments should always be
reassembled as tight as possible on any rebuild. There is no specific play limit to when the bone requires re-
shimming. If the bone is passing dynamic tests it is OK to use. Should there be significant wear to the curved
magnesium interfaces i.e. a prominent flat, these should be replaced but this has not been yet been seen in
these parts.

4.6.2 Buffers between segments

The two rubber buffers between segments must be in place, central to the axis and bonded to the outer edge of
the blue polymer segment. If one should become dislodged or damaged the bone must be disassembled and a
new rubber buffer added. See beginning of femur or tibia assembly section 3 for bonding. On reassembly
segment shim fit must be as tight as possible.

4.6.3 Shoulder Bolt and Segment Screw Tightness Check

Shoulder bolts and segment screws should be tightened to 3 Nm. This includes the M6 button head segment
screws behind the bone front polymer covers as well as the rear M6 screws.

4.7 Knee

4.7.1 Knee Meniscus

The knee meniscus is the blue polymer plate screwed on top of the knee tibia block. This can become worn with
use due to contact with the femur knee block. If this wear has created a significant groove in the plastic this
could affect free shear motion in the knee and should be replaced. Also, if wear has reached the meniscus
attachment screws, the meniscus must be replaced.

The bronze cross cable bushes will also wear, this is normal after a large number of tests. It will be more likely
the meniscus will wear before these bushes become a problem. These bushes will be new when the meniscus
assembly is replaced. All the bronze bushes are pressed in, if one should become lose it must be bonded in or
the meniscus replaced. See section 3 of this manual for disassembly and assembly.

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On disassembly it will be noticed that the four knees cross ligament cables will become kinked due to their fixed
position. This is normal and as long as the wire filaments are not cut or worn down, the end fittings not pulled
away from the cable, and threads are undamaged, they are suitable for reuse. This also applies to the other
eight ligament cables in the knee and the four bone stopper cables.

4.8 Sensor and Electrical Maintenance

4.8.1 General Electrical Maintenance

Check electrical cables and connectors for damage and wear. Particularly pay attention to the routing and
fixation of the cables in areas with large motion, e.g. around the knee and the point of exit of the cables. Also
check that cables have sufficient slack to allow the full range of motion in the knee joint when flexed in testing.
Repair broken cables or connectors as necessary.

4.8.2 Bone Maintenance

Warning: There may be tiny glass fibers on the outer surface of the bone that could be irritating to the skin. It is
advised to protect the hands with gloves when handling the bone and not to run your hand along the length of
the bone. The bone will likely see localized small cracks at the curved interface of the segments after some use.
This is normal and may not greatly affect the performance of the bone. If this cracking is severe the bone should
be replaced, however if the leg is still passing dynamic certification this would be at the discretion of the user. On
reassembly dust off the bone and magnesium segments contact surfaces with a soft brush. At this point, with the
bone disassembled also check for wear or damage to electrical components and repair as necessary. The
certification timing for gage calibration is stated in Table 14.

4.8.3 String Potentiometer Maintenance

The timing for sensor recalibration is stated in Table 14. For the string potentiometers check that the pull cables
are tight when the knee is assembled and not lose or deformed. If this is the case with injury channels ACL, PCL
and MCL, they will need replacing. The LCL is not an injury channel but does give information on the test.
Replacement is advised as well. On disassembly of the knee the string crimps should be checked for possible
slippage, the dimension from the crimp to the pot is 61.5 mm ±1. Also check the spring pull by gently pulling on
the pot wires; they should all feel the same. Be careful not to exceed the 38 mm travel. If the pots have not been
calibrated for a while it may be worth calibrating while the knee is dismantled. Also check for damage and wear
of electrical cables and connectors and repair as necessary.

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The blue plastic material used to make a number of leg parts can absorb moisture in high humidity
environments. The water absorption can weaken these parts and make them expand a little. This weakness
however should not affect the function of the Flex PLI but as a precaution if the leg is being used in extreme
environmental conditions it should be stored in a humidity-controlled room or chamber or placed in an air sealed
container or bag to prevent water absorption.

The Neoprene and rubber covers should always be removed from the leg when not in use to prevent stretching
and indentation of the covers.

All leg components should be stored as close to the test temperature conditions (16 to 24°C) as possible to allow
the leg to reach require temperature during its 4-hour soak time.

Section 6 Weight Specification

Leg Part Weight (kg) Weight Tol (kg)

Femur (133-5100) 2.46 ±0.12

Knee (133-5300) *4.28 ±0.21

Tibia (133-5500) 2.64 ±0.13

Femur, Knee &

9.38 ±0.30
Tibia

Flesh System **3.82 ±0.21

Leg Total 13.2 ±0.40

Table 13 Flex PLI GTR Mass

*If off board DAS is used knee has 0.1 kg allocated for cables.
** Includes tape and Velcro straps

The Flex PLI assembly mass and tolerances are given in Table 13. For dynamic certification tests (pendulum
and inverse) as well as regulatory vehicle tests, the leg must comply with the given limits.

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Section 7 Calibration and Certification Testing
7.1 Calibration and Certification Overview

Certification of the FLEX-PLI-GTR requires nine different procedures to ensure certified performance of all
components. All steps that may be performed by the users are discussed in this section. Calibration of string
potentiometers, accelerometer and bending moment strain gauges are not presented in this user manual, as this
requires operations only to be carried out by experienced and trained lab personnel. All certification tests shall
be conducted in a temperature-controlled test environment with a stabilized temperature of 20 ±2 °C and the
temperature shall be recorded. The subsequent steps of certifying the FLEX-PLI-GTR is given in Table 14.

Step Description When Required Pass-Fail Requirement

Femur Gauge 1. Annually, recommended 1. ±1.0% linearity full scale
0a
Calibration 2. After exceeding injury thresholds +10% 2. ±2.0% hysteresis full
Tibia Gauge for FLEX-GTR in an application test, scale
0b
Calibration recommended all gauges
String 1. Annually ±1.0% (VRCI-P-100A1)
0c Potentiometer
Calibration
Accelerometer 1. Annually 1. ±1.0% linearity full scale
0d
Calibration
Femur Assembly 1. Annually recommended 1. Femur centre bending
1a
Bending Test 2. After exceeding injury thresholds moment-deflection corridor
+10%, recommended 2. Tibia centre bending
Tibia Assembly
1b 3. After maintenance and/or component moment-deflection corridor
Bending Test
exchange, recommended
1. Annually recommended 1. MCL moment -
2. After exceeding injury thresholds elongation corridor
Knee Assembly
2 +10%, recommended 2. ACL and PCL moment -
Bending Test
3. After maintenance and/or component elongation corridors
exchange, recommended
1. Annually 1. Peak bending moment
2. After 10 vehicle tests max tibia 1, tibia 2, tibia 3 and
Dynamic
3 3. After exceeding injury thresholds +10% tibia 4
Pendulum Impact
4. After maintenance and/or component 2. peak elongation MCL,
exchange PCL and ACL
1. Annually 1. Peak bending moment
2. After 30 vehicle tests tibia 1, tibia 2, tibia 3 and
Dynamic Linear
4 3. After exceeding injury thresholds +10% tibia 4
Guided Impact
4. After maintenance and/or component 2. Peak elongation MCL,
exchange PCL and ACL
Table 14 FLEX-PLI-GTR certification steps

1 http://www.veci-vrci.com/VRCI-P-100A.pdf. ‘Industry standard wire wound and non-wire wound precision

potentiometers’.

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7.2.1 Introduction

Prior to the femur and tibia assembly certification, the bone cores are tested to established corridors. Each pair
of gages on impact side and none impact side (compression and tension) are tested individually to check correct
function and establish gage sensitivity at 380 Nm in the loaded direction. It is highly recommended that this
operation is carried out by Humanetics. Bone gage sensitivities must be taken from the bone gage calibration
sheet provided in the calibration report.

Passing static corridors is a regulatory requirement which help assure successful dynamic certification.

7.2.2 Femur and Tibia assembly Certification

This operation requires the use of a materials testing load frame machine with high definition load cell and
calibration fixture 133-8120.

Before testing a 3 to 7 mm thick Teflon sheet is fixed to a base plate at each end using double sided tape to
prevent the sheet sliding on the plate. See pictures below Figure 78.

Figure 78 Example of fixing Teflon sheet to base plate

Assemble the bone to the 133-8120 fixture; see drawing Figure 79 for details. Place the assembled fixture over
the Teflon sheets see Figure 81. Do not tighten the two cap head screws item 7 in Figure 79 at the end
segments of the assembly to allow free rotation.

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Figure 79 Bone and knee fixture 133-8120 for static assembly bending test femur shown

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ITEM QTY PART NO. DESCRIPTION

1 2 133-8125 PIVOT BASE
2 2 133-8124 SIDE PLATE, LEGS
3 1 133-8129 INSERT LEG PIVOT
4 2 133-8127 SPACER
5 4 133-8128 SHOULDER BOLT (11.90MM)
6 2 5000105 WASHER, FLAT M10
7 6 5000071 SCREW, SHCS M10 X 1.5 X 22
8 6 5000441 SCREW, SHCS M12 X 1.75 X 30
9 2 5000075 SCREW, SHCS M8 X 1.25 X 20
10 1 133-8150 BASE ASSEMBLY
11 2 133-8126 KNEE PIVOT SIDE PLATE
12 1 133-8121 KNEE CALIBRATION INSERT, FEMUR SIDE
13 1 133-8122 KNEE CALIBRATION INSERT, TIBIA SIDE
14 1 133-8105 KNEE LOADING PROFILE
15 1 133-8102 LEF LOADING SPIGOT
16 2 5000916 SCREW, MSSFP M8 X 12
Table 15 Parts List for static fixture 133-8120

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The femur bone is loaded centrally on the fourth plastic impact cover from the knee and on the tibia the fifth
plastic impact cover (which is the centre of each bone). The loading spigot is connected to a high definition load
cell on a load frame. Connect assembly to recording equipment.

The loading spigot is at zero load just touching the impact cover. Each bone assembly is loaded to 380 Nm.
Check deflection/moment output must be inside corridor see Figure 82 and 83. Temperature for this test must be
between 20 ±2 °C. Note that the loading path from the machine must have no rubber damping otherwise the
load curve will be inaccurate. To calculate moment loading centres, femur is 330mm and tibia 410mm. For femur
moment MF = [F (N)/2] x0.165 (m) and for tibia MT = [F (N)/2] x0.205 (m). Loading rate is to be between 10 and
100 mm/min.

Figure 81 Bone Assembly Fixture (femur shown under bending)

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350

300

250
Moment (Nm)

200

150

100

0
0 5 10 15 20 25
Deflection (mm)
Figure 82 Femur assembly certification corridor moment vs. deflection showing typical results

400

350

300

250
Moment (Nm)

200

150

100

0
0 10 20 30
Deflection (mm)
Figure 83 Tibia assembly certification corridor moment vs. deflection showing a typical result

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This operation requires the use of a materials testing machine with high definition load cell and some parts from
calibration fixture 133-8120 see Figure 80. Temperature for this test must be between 20 ±2°C.
Locate the femur insert into the femur knee block, the femur insert is 3mm longer than the tibia insert so it is
important the correct insert is in the correct knee block or results will be wrong. Fit 2x M8 x 35 BHCS and tighten,
then fit the 2x M8 x 30 set screws on the opposite side and torque all screws to 8 Nm. Follow the same
procedure for the tibia insert. Assemble the fixture as shown ensuring the impact side is on the top and the two
blue plastic covers have been removed along with the accelerometer if fitted and double-sided tape. It is
important to check that the two knee blocks are aligned before starting the test to remove any shear or twist in
the assembly. A procedure like that used in figure 91 can be used and double checked with a straight edge.

Place assembly over the center of the base plate with 3.2 mm thick Teflon sheets fitted with double sided tape
as in Figure 78.

The testing machine must be fitted with Ø100mm ‘D’ shaped profile part 133-8105, see Figure 80. The center of
the profile must be aligned with the top of the meniscus; a line is marked on the loading profile for this visual
alignment. Plug string pots into recording equipment. A piece on Neoprene minimum size 85 x 50 x 5mm thick is
placed over the loading point to prevent damage to the knee. The 85 min dimension is the knee width
dimension. This Neoprene is the same material used in the covers. The loading profile is brought down to
contact the Neoprene at the zero-load point. Then the test loading is started.

The knee is then loaded to 4 KN, speed rate must be between 10 and 100 mm/min. Calculate the bending
moment at knee with: Mk = [F/2] x 0.2.

LCL, ACL, PCL, and MCL string pot deflections are recorded. The LCL deflection is only checked for function in
this test as it would be in compression, (negative). The results must be inside the corridors given in Figure 85
and 86. If the result does not fit into the corridor the springs may be tightened or loosened. Humanetics
recommends the nuts are not adjusted more than 1mm from the nominal flush washer position to the knee block
to avoid affecting the designed full range of motion of the knee. The knee ligament outputs should all be positive;
the LCL will bottom out between 2 and 4mm.

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450
Knee bending moment (Nm)

400

350

300

250

200
moment L
150

100 moment U

0
0 5 10 15 20 25 30

MCL Elogation (mm)

Figure 85 Figure MCL sensor elongation Upper and lower corridor

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ACL and PCL elongation (mm)

ACL
10

2 PCL

0
0 1000 2000 3000 4000

-2

Force (N)

Figure 86 Figure ACL and PCL upper and lower corridors

7.3.1 Frontone Test Fixture for Static Certification

Known as the FLEX STATIC this certification fixture automatically carries out the femur, knee and tibia static
certification. See figure X below. Bone gage calibration is also possible with this device.

The system consists of an electric spindle drive which lifts up the table. Reference force and table position are
recorded during the test.

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The dynamic pendulum certification test is carried out on the Dynamic Certification Test Rig, Part Nr 133-8400 or
similar and is diagrammatically shown in Figure 87. Only 7 channels are required and must meet the GTR9
requirement see Table 15. Femur zero crossover timing and max and min corridors are also shown for functional
guidance and will be monitored.

For assembly instructions of 133-8400 test rig refer to section 8.2.

The leg should be tested with it’s on board DAS to obtain complete certification of the tool.

Figure 88 Diagram of Dynamic Pendulum Fixture

This test is carried out at build and mandatory after every 10 vehicle tests. This test can be carried out at any
time if required to check the leg before testing. The test must be carried out at a stabilized temperature of 20°C
±2 and temp must be recorded. The leg assembly is tested with the flesh cover parts fitted and the leg is upside

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down, so that the leg pivots from the bottom of the tibia. This is to increase the amount of test energy to have
similar loading level to a vehicle impact; an additional 5.0kg mass is also added to the femur end.

8.1.1 E-Liner FLEX ZERT

The E-Liner FLEX ZERT is a purely electrically driven easy to operate test rig for both dynamic certifications of
the Flex PLI. Therefore, both the pendulum and inverse certification can be performed with very high
repeatability. For the pendulum test the Flex leg is attached to the release latch then is lifted up automatically to
the regulated height. The leg can then be dropped under its own weight to the impact face on the front of the test
reg.

For the inverse test a linear guided impactor is fired according to the GTR9 specification (see section XX) to
strike the leg. The speed accuracy is +/- 0.05 km/h so provides very good repeatability.

Furthermore, the TRL upper and lower leg form certification can also be performed with this test rig.

Figure 89 Frontone FLEX ZERT showing pendulum operation

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Figure 90 FLEX ZERT, pendulum arm folded back in inverse condition with control box

8.2 Leg Preparation for Pendulum Dynamic Certification

Step 1: Check the alignment of the blue upper and lower knee covers (133-5304, 133-5305)
Step 2: Check the eight M8 set screws shown in Figure 9189 are tightened to 8 Nm;

Figure 91 Check screws with 8 Nm torque

Step 3: After 60 vehicle tests remove the knee blue front covers and check the 4x M8 button head screws
attaching the legs are tightened to 8 Nm;

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Step 4: Check the four stop cable clearances passing through the femur are set to 9.1 mm and 10.3 on the tibia.
See Figure 92 a special tool 133-5112 is used for this;

Figure 92 Stop cable clearance adjustment using setting tool

Step 5: Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test.
Using two equal height blocks push down on the back of the knee for y direction and also on one side of the
knee for x direction as shown in Figure 93. A straight edge can be used to double check alignment after any
adjustment on two sides.

Figure 93 Recommended method to align knee to remove any twist and shear

Step 6: Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm. The impact
covers would need removal to check front segment screws;

Step 7: Remove the aluminum launch guide (Figure 55 item 18, Part Nr 133-5103,) U shaped bracket fitted to
the top of the femur along with the black protective cover (Figure 55 item 28, Part Nr 133 - 5516);

Step 8: Attach the ballast weight (Part Nr 133-8436) as shown in Figure 94 to the top of the femur using two M8
x 50 long cap head screws;

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 94 of 109

Step 9: Remove the black protective cover (Part Nr 133 – 5516) from the tibia bottom and attach the Pivot Hinge
(Part Nr 133-8418) as shown in Figure 95 using four M6 x 18 long screws.

Figure 95 Attaching Pendulum Rig Pivot hinge

Step 10: See next step in section 8.4 for rig preparation. The checking and adjustment of the pendulum Impact
Block (Part 133–8423) must be done with a bare leg without the suit. Check the Impact block is adjusted to the
specification

Step 11: Fit the flesh and skin covers as described in 3.4.4 allowing for the electrical wires to exit at the top of
the (upside down) leg. The leg is now ready to be hung on the rig.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 95 of 109

Suspend the bare leg (without suit) on the fixture with the Pivot Hinge in the Pivot Clearance Block and the
Shoulder Bolt. Check that the distance from the bottom of the Impact Block is 30 ± 1mm above the top of the
plastic blue Meniscus of the knee and 13 ± 2 mm from the front of the impact face (point nearest to the leg) to
the impact segments of the tibia. See Figure 96. Adjust the height of the Impact Block by moving the Impact Bar
Weldment up or down (4 screws that mount tube to frame). Adjust the horizontal Impact Block to Leg distance to
13 ± 2 mm. Shims can be added to the back of the Impactor Block or the Pivot Clearance Block if necessary.

Figure 96 Checking the Impact Block position adjustment

Next step is to make a loop of steel wire rope of the proper length, such that the drop angle matches the
required suspension angle of 15 °± 1° above horizontal. Suspend the leg with the Pivot Hinge to the Pendulum
Rig. The leg is lifted up to the release mechanism (Figure 97) and held in position with the steel wire rope
attached to the ballast weight. Adjust the loop length to the required suspension angle of 15 °± 1°. Check the
angle with a digital inclinometer laid on the back of the knee. The steel rope is tied to the ballast weight via an
eye bolt which can be used for fine height adjustment. The Pendulum Rig is now ready for running a test.

Figure 97 Examples of release latches

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 96 of 109

The test facility used for the certification must have a stabilized temperature of 20 ±2 °C during the certification
and the temperature is to be recorded.

Step 1. Hook up the sensors on the Data Acquisition System (DAS)

Step 2. Fit the leg to the pivot block on the rig using the M10 Socket Head Shoulder Screw (SHSS). Route the
disconnect wire as required out of the end of the tibia or below the knee depending on type of DAS and tape up
to the rig so that it does not interfere with the free swing motion of the leg when tested. If using off board DAS
the wires are routed out of the top of the leg.

Step 3. With the leg hanging down vertically, start up and initiate the DAS and set the DAS such that the
sensors are zeroed to zero sensor output in this position. Important: The leg sensors are zeroed in the
vertical impact position before lifting to 15 degree above horizontal.

Step 4. The leg is lifted up to the release mechanism and held in position using the steel wire rope loop attached
to the ballast weight. The rope has been made so that the angle of the leg before release is 15° above the
horizontal. Check once more the angle with a digital inclinometer on the back of the knee. The steel rope is tied
to the ballast weight via an eye bolt, which can be used for fine height adjustment.

WARNING: After the impact the leg swings back violently and can seriously injure anyone standing in the
rebound area. Releasing the leg must be done from the side of the rig; under no circumstances should anyone
be behind the leg or in its swing plane during testing .It is highly recommended that a safety barrier is erected in
the swing/rebound area ensuring no one is inside the drop zone during release to avoid any injury. The release
can be switched through a safety system and a control box that can only be operated with the barrier closed
ensuring that no one is in close range of the rebounding leg.

Step 5. Arm the DAS system and release the leg. The trigger for data collection can be from the accelerometer
on the leg, started manually or from a speed gate. After initial impact the leg will continue to bounce, where
possible the leg should be caught or stopped to prevent this. The springs in the knee and the elastic response
from the rubber flesh create a strong rebound. If there is any doubt about safety allow the leg to bounce after
impact.

Step 6: Detach leg from rig and remove the skin and flesh after each test.

If a test is to be repeated the leg should rest for 20 minutes minimum before repeating. If another flesh set is
used the test does not need to wait 20 minutes.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 97 of 109

All data shall be filtered CFC180. The certification corridors of all the GTR9 injury channels are given in Table
15. These peak values are to be within 200 ms after impact.

Peak Moment @ Tibia

Certification Channels

Peak MCL Elongation

Peak PCL Elongation
Peak ACL Elongation
GTR Pendulum

Gage 2

Gage 3

Gage 4
Gage 1

Unit Nm mm

Upper 272 219 166 111 10.5 5.0 24.0

Lower 235 187 139 90 8.0 3.5 20.5

Table 16 Pendulum test regulation corridors, peak values within 200 ms after impact

8.6 Pendulum Femur Corridors

The femur corridors are not a regulatory requirement they are for monitoring to assess the satisfactory condition
of the femur. Zero crossover timing and max and min corridors are listed below.

Pendulum Femur Zero Cross Timing Corridors (for monitoring)

Femur gage 1: 164 to 194 ms

Femur gage 2: 164 to 194 ms
Femur gage 3: 164 to 194 ms
Pendulum Dynamic

Peak Moment @

Peak Moment @
Femur corridors

Femur Gauge 3
Femur Gauge 1

Femur Gauge 2

Units Nm

Upper 205.5 149.9 96.0

Lower 173.5 120.5 70.8

Table 17 Max and min pendulum femur corridors

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 98 of 109

After the initial manufacturers inverse test the leg is recommended to be inverse tested before each vehicle test
series and mandatory after every 30 car tests. The preparation for the leg and execution of the test is described
in this section. The 7 injury channels must meet the test corridors as stated in the GTR9 regulation. Femur
corridors are also shown for functional guidance only. The leg should be tested with it’s on board DAS to obtain
complete certification of the tool.

9.2 Inverse Test Description

The inverse test is a dynamic calibration test where the fully assembled leg is suspended stationary vertically
±2° from a sprung hook which releases within 10 ms after impact. The leg is struck with a linear guided impactor
of 8.15 ± 0.1 kg mass including the honeycomb face with an impact velocity of 11.1 ±0.2 m/s (40 kph, the same
speed as the GTR9 vehicle test). The linear guided impactor face must contact the knee within ±2 mm vertically
from the top of the blue Meniscus (top of tibia knee block). A schematic of the test set up is shown below. See
Section 8.1.1 Frontone FLEX ZERT for example of a test rig.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 99 of 109

9.3 Preparation of the Inverse Test set up

The linear guide impactor face is covered with 5052 Aluminum honeycomb with a crush strength of 75 PSI ±10.
The size of the honeycomb is width 200 ± 5mm, length 160 ± 5mm and depth 60 ± 2mm. To ensure a consistent
and good level of repeatability the honeycomb should either have a 3/16 inch cell size or a ¼ inch cell size. The
honeycomb should have a density of 2.0 pcf (pounds per cubic foot) in combination with a 3/16 inch cell size or a
density of 2.3 pcf in combination with a ¼ inch cell size. A pre-crush honeycomb is recommended.

The honeycomb block is covered with paper cloth of less than 1mm thick. See Figure 99. The paper cloth is
wrapped around the honeycomb and taped at the back to hold in position. The paper helps to prevent damage to
the leg covers.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 100 of 109
©2018 Humanetics Innovative Solutions
It is recommended to fix the Honeycomb to the impactor using strong double sided tape to help maintain position
on impact. The top of the impactor plate must be in line with the honeycomb at time of first contact and the upper
edge of the honeycomb must be in line with the knee joint (top of blue tibia knee block) ± 2 mm.

On impact the leg is to be released from the hanging bracket within 10 ms to ensure free flight condition.

Figure 99 Paper cloth wrapping of honeycomb

9.4 Impactor Friction, Stroke Phases and Speed Measurement

The impactor free travel and travel through impact are important to obtain good results. The linear guided
impactor dynamic friction during free travel should be less than 100 N to avoid speed reduction. To measure
friction an accelerometer mounted to the impactor would be required to measure acceleration in the free stroke
phase. Refer to document GTR9-5-15 for measurement information. It is advised all inverse rigs carry out this
test. Humanetics recommends a free travel of 70mm before impact and 190 to 220 mm after first contact to
ensure all kinetic energy from the impactor is transferred.

The speed must be measured in the free travel phase, ideally at a sample rate around 100 KHz due to the high
speed and as close to the impact point as possible.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 101 of 109
©2018 Humanetics Innovative Solutions
9.5 Leg Preparation for Dynamic Inverse Test

Step 1: Check alignment of the blue upper and lower knee covers (133-5304, 133-5305)

Step 2: Check the eight M8 set screws shown in Figure 89 are tightened to 8 Nm.

Step 3: After 60 vehicle tests remove the knee front covers and check the 4x M8 button head screws attaching
the legs are tightened to 8 Nm

Step 4: Check the four stop cable clearances passing through the femur are set to 9.1 mm and 10.3 on the tibia.
See figure 90 a special tool 133-5112 is used for this.

Step 5: Check knee blocks are aligned to ensure knee is not twisted or in a shear condition before the test.
Using two equal height blocks push down on the back of the knee for y direction and also on one side of the
knee for x direction as shown in Figure 91. A straight edge can be used to double check alignment after any
adjustment.

Step 6: Check all segment screws and side aluminum shoulder screws are tightened to 3 Nm.

Step 7: Fit the flesh and skin covers as described in 3.3.4. Check all wires are correctly positioned to avoid
damage and any exit wires are restrained.

Step 8: Hook up the sensors on the Data Acquisition System (DAS) as applicable

9.6 Running a Dynamic Inverse Test

The test facility used for the certification must have a stabilized temperature of 20 ±2 °C during the certification
and the temperature is to be recorded.

The pitch angle of the impactor (rotation around y-axis) at the time of first contact shall be within a tolerance of 0
± 2° in relation to the lateral vertical plane. The roll angle of the impactor (rotation around x-axis) at the time of
first contact shall be within a tolerance of 0 ±2° in relation to the longitudinal vertical plane. The yaw angle of the
impactor (rotation around z-axis) at the time of first contact shall be within a tolerance of 0 ±2°.

Step 1. Suspend the leg on the inverse test rig on the release mechanism with its launch guide.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 102 of 109
©2018 Humanetics Innovative Solutions
Step 2: Make sure the launch guide at the top of the femur is locked tilting 15° towards the impactor. Lock the
guide in position using the two M6 screws both sides. This allows the leg to hang vertically on the spring loaded
release mechanism. See Figure 100 below.

Figure 100 Launch guide with 15° tilt toward guided impactor

Step 3. With the leg hanging down vertically, start up and initiate the DAS and set the DAS such that the sensors
are zeroed to zero sensor output in this position. Important: The leg sensors are zeroed in the vertical impact
position.

WARNING: After the impact the leg is thrown violently away from the test rig and can seriously injure anyone
standing in the flight area. It is highly recommended that a safety barrier is erected in the flight area ensuring no
one is inside this danger zone during the test to avoid any injury.

Step 4. Arm the DAS system and release the linear guided impactor. The trigger for data collection can be from
the accelerometer on the leg, contact switch or from a speed gate.

Step 5: Conduct test

Step 6: Remove outer skin cover and inner flesh system after each test

If a test is to be repeated the leg should rest for 20 minutes minimum before repeating. If another flesh set is
used the test does not need to wait 20 minutes.

9.7 Data Processing

All data shall be filtered CFC180. The Inverse Certification corridors of all the GTR9 injury channels are given in
Table 16. Peak values shall be within 50 ms after impact.

Peak Moment @ Tibia

GTR Inverse Dynamic

Peak MCL Elongation

Peak PCL Elongation
Peak ACL Elongation
Calibration Results

Gauge 2
Gauge 1

Gauge 3

Gauge 4
Units Nm mm

Upper 272 252 192 108 10.0 6.0 21.0

Lower 230 210 166 93 8.0 4.0 17.0

Table 18 Inverse test regulation corridors, peak values within 50 ms after impact

For further details of the test requirements refer to document ECE/TRANS/WP.2.9/GSRP/2009/26

9.8 Inverse Femur Corridors

The femur corridors are not a regulatory requirement, they are for monitoring to assess the satisfactory condition
of the femur. Zero crossover timing and max and min corridors are listed below.

Inverse Femur Zero Cross Timing Corridors (for monitoring)

Femur gage 1: 28 to 58 ms
Femur gage 2: 28 to 58 ms
Femur gage 3: 29 to 59 ms
Peak Moment @

Peak Moment @

Peak Moment @
Inverse Dynamic
Femur corridors

Femur Gauge 3
Femur Gauge 1

Femur Gauge 2

Units Nm

Upper 227.6 164.8 92.3

Lower 166.6 118.6 64.4

Table 19 Max and min femur inverse corridors

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 104 of 109
©2018 Humanetics Innovative Solutions
Section 10 Vehicle Test
10.1 Introduction

For the vehicle test a special launch plate or pusher is required which is attached to a firing ram or launch
system, for an example see Figure 101. The design of the pusher and stroke length is important to maintain
stable release conditions when the leg leaves the launcher. The leg is fired at the vehicle at 40 kph or 11.1 m/s ±
0.2.

For the specifications and requirements of the test refer to ECE/TRANS/WP29/GSRP/2009/26

10.2 Leg Preparation for Car Test

Step 1 Check alignment of upper and lower blue knee covers (133-5304, 133-5305)
Step 2 Check knee block alignment (no twist, no shear) with straight edge
(Figure 91) align if necessary.
Step 3 Fit flesh and skin covers as described in 3.3.4. Check all wires are in position and restrained.
Step 4 Hang assembled legform in launch apparatus
Step 5 Initiate DAS and zero sensors with leg hanging down vertically in launch apparatus
Step 6 Conduct test
Step 7 Remove outer skin and flesh after each test

If a test is to be repeated the leg should rest for 30 minutes minimum before repeating.
If another flesh set is used the test does not need to wait 30 minutes.

10.3 Injury Thresholds

There are 7 injury channels in the GTR9 regulation, the thresholds for these are listed in the table below.

Instrument Channel Channel Qty Threshold Value

Tibia Moments 4 340 (380*) Nm
MCL Elongation 1 22 mm
ACL Elongation 1 13 mm
PCL elongation 1 13 mm
Total 7
Table 20 Threshold values for injury channels

*Injury threshold applies to relaxation zone (stiff areas of the bumper, like tow hook locations max 264 wide).
This 380 relaxation threshold can be restricted in a contracting party’s domestic legislation if it decides such
restriction is appropriate.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 105 of 109
©2018 Humanetics Innovative Solutions
10.4 Leg Loading limits in free flight

The loading level of the impactor during free flight for tibia bending moments are recommended to be less than
+/- 15 Nm 30 ms before impact and for knee ligaments (MCL, ACL, PCL) elongations are recommended to be
less than +/- 1mm. If there are oscillations in the leg when fired, adjusting the height of the bone pushing pads
on the launcher plate should prevent this. The thicker Neoprene covers of the femur and tibia are softer than the
knee which can generate more pushing load at the knee than over the bones creating an oscillation in flight. The
aim would be to get an even push along the whole length of the leg. Depending on the acceleration and stiffness
of the pusher different users will need different pusher pad heights to avoid oscillation.

The side link shoulder screws on the aluminium segments can become loose in testing. It is an option to use a
weak thread lock on these to prevent them coming loose.

WARNING! VIOLENT REBOUND!

After impact with the vehicle the leg can be thrown high into the air or can be deflected some distance in any
direction depending on the geometry of the bumper. Therefore, it will be important to protect anyone exposed in
the test lab. Laboratory staff must be clear of the test site and they must be behind suitable barriers during the
launch.

10.5 Determination of Impact Speed

During the vehicle tests, the impact velocity must be measured during free flight, ideally at a sample rate around
100 KHz due to the high speed. To correctly determine the impact velocity, it is recommended either to calculate
it from the signal of the standard accelerometer in the knee section (see table 5) or to measure it using an
external light barrier. Such a light barrier should be positioned as close as possible to the impact location of the
vehicle. Information provided by FlexPLI users indicates that the height positioning of the light barrier (i.e. at the
knee section, the foot section or the top end of the impactor) does not lead to considerable differences in the
velocity measurement provided that the impactor achieves a stable free flight as required in section 10.4., using
an appropriate pusher plate / launch system. An example for such a pusher plate / launch system is shown in
section 10.7

A catch rope attachment bracket is available to attach at each end of the leg allowing a 4 point rope attachment.
The protective covers are removed and replaced with high strength aluminum Catch Rope Bracket, see Figure
101. This allows the leg to be tied into a frame preventing any damage or injury from rebound. The ropes are
quickly retracted after impact to keep the leg inside the frame.

Figure 101 Optional catch rope bracket 133-5034

10.7 Impactor Pusher Plate

To obtain a stable release the pusher system must be very stiff and to help with acceleration away from the ram
the pusher assembly should have low mass. The impactor pusher guides must be set to 113mm as shown in
Figure 102 below.

Figure 102 Impactor guide width setting 113mm

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 107 of 109
©2018 Humanetics Innovative Solutions
Figure 103 Humanetics Launch plate Part No 133-8200 (Aluminum and Carbon Fiber)

The interface plate that attaches to the launcher is drilled to match customer hole pattern.

133-9900 FLEX PLI GTR USER MANUAL Rev K Page 108 of 109
©2018 Humanetics Innovative Solutions
Section 11 Manual Update Log

Rev. H, Jul. 2015

Page 2: Added lead material statement

Rev. J, July 2016

Added section 7.4, FLEX STATIC information. Removed 8.2 Pendulum rig assembly instruction, test rig
picture and parts table. Added section 8.1.1 FLEX ZERT information.

Rev. K, July 2018

Updated ISO code to Nov 2016 standard; Section 8.5 and Table 16: Peak value timing for pendulum
certification corrected to 200 ms was 250; Section 9.3: Added “ A pre-crush honeycomb is
recommended.” as a recommendation for inverse testing; Updated address;

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