Humanetics Hybrid III 5th Female User manual

880105-9900 User Manual Hybrid III 5th Female Rev G Page 1 of 86
© 2020 Humanetics Innovative Solutions
Hybrid III 5th Female
User Manual
880105-000-XH

880105-9900 User Manual Hybrid III 5th Female Rev G Page 2 of 86
© 2020 Humanetics Innovative Solutions
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: [phone]
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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

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© 2020 Humanetics Innovative Solutions
Table of Contents
Section – 1 Introduction ................................................................................................................................6
1.1 Foreword.................................................................................................................................................6
1.2 Manual Overview ....................................................................................................................................6
1.2.1 Appendices..................................................................................................................................6
1.2.2 SAE Documents..........................................................................................................................6
1.2.3 SAE Test Definitions ...................................................................................................................6
1.2.4 Abbreviations...............................................................................................................................7
1.3 Construction............................................................................................................................................8
1.4 Clothing...................................................................................................................................................8
1.5 Instrumentation .......................................................................................................................................9
1.6 Special Tools.........................................................................................................................................11
Section 2 – Head and Neck Removal.........................................................................................................12
2.1 Disassembly......................................................................................................................................12
2.2 Reassembly......................................................................................................................................14
2.3 Inspection..........................................................................................................................................14
Section 3- Head Assembly..........................................................................................................................15
3.1 Disassembly......................................................................................................................................16
3.2 Reassembly......................................................................................................................................16
3.3 Inspection..........................................................................................................................................16
Section 4 – Neck Assembly ........................................................................................................................18
4.1 Disassembly......................................................................................................................................19
4.2 Reassembly......................................................................................................................................20
4.3 Inspection..........................................................................................................................................20
Section 5 – Upper Torso Assembly ............................................................................................................21
5.1 Disassembly......................................................................................................................................24
5.2 Reassembly......................................................................................................................................25
5.3 Inspection..........................................................................................................................................26
5.4 Chest Deflection Disassembly..........................................................................................................30
5.5 Chest Deflection Reassembly...........................................................................................................30
5.6 Chest Deflection Inspection..............................................................................................................31
5.7 Shoulder Assembly...........................................................................................................................32
5.8 Shoulder Disassembly......................................................................................................................33
5.9 Shoulder Reassembly.......................................................................................................................34
5.10 Shoulder Inspection........................................................................................................................34
Section 6 – Lower Torso Assembly ............................................................................................................35
6.1 Lumbar Disassembly ........................................................................................................................37
6.2 Lumbar Reassembly.........................................................................................................................37
6.3 Pelvis Disassembly...........................................................................................................................38
6.4 Pelvis Reassembly ...........................................................................................................................40
6.5 Lower Torso Inspection ....................................................................................................................40
Section 7- Arm Assembly............................................................................................................................41
7.1 Disassembly......................................................................................................................................42
7.2 Reassembly......................................................................................................................................42
7.3 Inspection..........................................................................................................................................42
Section 8- Leg Assembly ............................................................................................................................43
8.1 Leg Disassembly ..............................................................................................................................44
8.2 Leg Reassembly...............................................................................................................................44
8.3 Leg Inspection ..................................................................................................................................44
8.4 Lower Leg Disassembly....................................................................................................................46
8.5 Lower Leg Reassembly ....................................................................................................................46
8.6 Lower Leg Inspection........................................................................................................................46
8.7 Ankle Disassembly ...........................................................................................................................48
8.8 Ankle Reassembly............................................................................................................................48
8.9 Ankle Inspection ...............................................................................................................................48
8.10 Instrumented Leg Disassembly ......................................................................................................49

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8.11 Instrumented Leg Reassembly.......................................................................................................50
Section 9– Calibration Tests.......................................................................................................................51
9.1 Head Drop Test ................................................................................................................................51
9.2 Neck Test..........................................................................................................................................53
9.3 Thorax Impact Test...........................................................................................................................58
9.4 Knee Impact Test..............................................................................................................................61
9.5 Knee Slider Test ...............................................................................................................................63
Section 10 – Inspection Tests.....................................................................................................................66
10.1 External Measurement Procedure..................................................................................................66
10.2 Hip Joint Range of Motion ..............................................................................................................70
10.3 Design Reference, Foot Test..........................................................................................................72
10.4 Design Reference, Ankle Motion Test............................................................................................74
10.5 Design Reference, Torso Flexion Test...........................................................................................78
Section 11 – Appendices ............................................................................................................................81
11.1 Appendix A .....................................................................................................................................81
11.1.1 Accelerometer Handling Guidelines........................................................................................81
11.2 Appendix B .....................................................................................................................................83
11.2.1 Guidelines for Repairing Flesh................................................................................................83
11.3 Appendix C .....................................................................................................................................84
11.3.1 Joint Adjustment Procedures ..................................................................................................84
11.4 Appendix D .....................................................................................................................................85
11.4.1 Axial Integrity of the Neck........................................................................................................85
11.5 Appendix E .....................................................................................................................................85

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List of Figures
Figure 1.1 – Accelerometer Location in Dummy.........................................................................................10
Figure 2.1- Disassembling the Head and Neck ..........................................................................................12
Figure 2.2 – Neck Compression Tool .........................................................................................................13
Figure 2.3 – Neck Removal.........................................................................................................................13
Figure 3.1 – Head Assembly.......................................................................................................................15
Figure 4.1 – Neck Assembly.......................................................................................................................18
Figure 4.2 - Nodding Block Orientation.......................................................................................................19
Figure 5.1 – Upper Torso Front View..........................................................................................................21
Figure 5.2 – Upper Torso Front View..........................................................................................................22
Figure 5.3- Upper Torso Side View.............................................................................................................23
Figure 5.4- Chest Depth Gage (880105-811).............................................................................................26
Figure 5.5- Chest Depth Gage (880105-813).............................................................................................27
Figure 5.6- Chest Depth Measurement Setup............................................................................................28
Figure 5.7- Chest Deflection Transducer Assembly ...................................................................................29
Figure 5.9- Shoulder Assembly Exploded View..........................................................................................32
Figure 6.1 – Lower Torso Front View..........................................................................................................35
Figure 6.2- Lower Torso Side View.............................................................................................................36
Figure 6.3 – Lower Torso Top View............................................................................................................36
Figure 6.4- Lumbar Spine Assembly...........................................................................................................39
Figure 6.5- Pelvic Reference.......................................................................................................................40
Figure 7.1- Arm Assembly Exploded View..................................................................................................41
Figure 8.1- Leg Assembly Exploded View..................................................................................................43
Figure 8.2- Sliding Knee Exploded View.....................................................................................................45
Figure 8.3 – Ankle Assembly Exploded View .............................................................................................47
Figure 8.4- Instrumented Lower Leg...........................................................................................................49
Figure 9.1- Head Drop Test Setup Specifications.......................................................................................53
Figure 9.2 – Neck Pendulum Arm Specifications .......................................................................................56
Figure 9.3 – Neck Extension Test Setup Specifications.............................................................................57
Figure 9.4 – Neck Flexion Test Set-Up Specifications ...............................................................................57
Figure 9.5 -Thorax Impact Test Setup Specifications.................................................................................60
Figure 9.6 – Hystersis Definition.................................................................................................................61
Figure 9.7 – Knee Impact Test Setup Specifications..................................................................................63
Figure 9.8 – Knee Slider Test Setup Specifications ...................................................................................65
Figure 10.1 – External Dimension Measurement........................................................................................68
Figure 10.2- Hip Joint Range of Motion Test Setup....................................................................................72
Figure 10.3 – Compression Test Setup......................................................................................................73
Figure 10.4- Foot Compression Test Performance Specifications.............................................................74
Figure 10.5 – Leg Reference Planes ..........................................................................................................76
Figure 10.6- Ankle/Foot Reference Planes.................................................................................................77
Figure 10.7- Torso Flexion Bracket Assembly............................................................................................79
Figure 10.8 – Torso Flexion Test Setup......................................................................................................80

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© 2020 Humanetics Innovative Solutions
Section – 1 Introduction
1.1 Foreword
In the late 1980’s the Center for Disease Control (CDC) awarded Ohio State University a grant to develop
multi-sized test dummies based on the Hybrid III design. To aid in this endeavor, the Mechanical Human
Simulation Subcommittee of the Society of Automotive Engineers (SAE) formed a Task Group to define
the specifications for an adult size small female dummy which would have, at least, the same level of
biofidelity and measurement capacity as the 50th Hybrid III Dummy.
The Hybrid III Small Female Test Dummy is based on the characteristic size and weight measurements
taken from anthropometry studies of the 5th percentile adult female. Its impact response requirements for
the head, neck, chest, hip, knee and ankle were extrapolated from the biofidelity requirements of the
Hybrid III mid-size male dummy. (see Mertz, H. J., Irwin, A. I., Melvin, J. W., Stalnaker, R. L., Beebe, M.
S., “Size, Weight, and Biomechanical Impact Response Requirements for Adult Size Small Female and
Large Male Dummies”, SAE #890756, SP-782, 1989.) The Hybrid III small female dummy is designed to
represent the lower extreme of the United States adult population.
1.2 Manual Overview
1.2.1 Appendices
Several guidelines and procedures apply to various parts throughout the dummy, and are included in the
appendices for easier reference. First, when handling an instrumented dummy, improper techniques can
damage instrumentation, particularly accelerometers. Appendix A contains guidelines for safe handling of
instrumented dummies. Second, the vinyl flesh of dummies can be damaged, but is often repairable.
Appendix B contains instructions for repairing dummy flesh. Third, procedures for adjusting the joints
throughout the dummy are included in Appendix C.
1.2.2 SAE Documents
In addition to the attached appendices, other SAE publications are particularly useful when working with
the Hybrid III dummies. SAE J211 provides the most recent guidelines and procedures for dummy
instrumentation and filtering. SAE Information Report J1733 illustrates the instrumentation available for the
Hybrid III dummy, along with descriptions of how to apply the positive right-hand rule sign convention.
1.2.3 SAE Test Definitions
Calibration Test:
Calibration tests are specified for dummy responses which could affect dummy measurements that are
used by government and safety engineers to assess occupant injury potential. Calibration tests are
performed by the dummy manufacturer to assure that a new component or assembly meets the SAE
specified response requirements. The crash dummy user will periodically perform the calibration tests to
assure the dummy is maintained at the SAE specified performance levels.
Inspection Test:
Inspection tests are supplemental to the calibration tests to insure that a component meets its design
intent. They are performed by the dummy manufacturer on new parts. The dummy user may conduct
inspection tests when a part is damaged or replaced.

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1.2.4 Abbreviations
The following threaded fastener abbreviations are used in this manual.
SHCS………………………….Socket Head Cap Screw
FHCS………………………….Flat Head Cap Screw
BHCS………………………….Button Head Cap Screw
SHSS………………………….Socket Head Shoulder Screw
SSCP………………………….Socket Screw, Cup Point
RHMS…………………………Round Head Machine Screw

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1.3 Construction
The skull and skull cap are both one-piece cast aluminum, with a removable one-piece vinyl head and
skull cap skin. The skull cap is removable for access to the head instrumentation. The vinyl skin is
tuned to give human-like response to forehead impacts.
The neck has a biofidelic “angle versus moment” response in both dynamic flexion (forward bending)
and extension (rearward bending) articulations.
A neck cable controls stretching responses, and increases the neck’s durability to high axial tension
forces.
The two-piece aluminum clavicle and clavicle-link assembly have cast integral scapulae to prevent
interface with shoulder belts.
Six spring steel ribs with polymer-based damping material approximate the human chest force-
deflection response characteristics. The sternum assembly connects to the front of the ribs and
incorporates a slider for a chest deflection transducer to measure rib cage deflection relative to the
thoracic spine.
A straight lumbar spine gives a sitting posture to simulate a person of larger stature in the driving
position.
The pelvis has a human shape and comes equipped with load cell replacements for pelvis
submarining-indicating transducers.
A knee slider mechanism is used that consists of steel sliders with energy absorbing molded rubber
mounted on aluminum knees. This allows for displacement of the tibia relative to the femur, simulating
ligament response.
The leg assemblies are steel tubes covered with vinyl. The legs are interchangeable with instrumented
versions.
Constant friction movable joints are used that need few adjustments and provide consistent
articulations.
The standard model has a "seated" pelvis construction. A “sit/stand" pelvis version is optional as are a
neck covering for airbag testing, a deformable face for steering wheel rim testing, and a deformable
abdomen for lap belt submarining and steering wheel rim evaluations.
1.4 Clothing
When used in testing, the dummy should wear snug-fitting cotton knit T-shirt and pants. The neckline
should be small enough to prevent contact between a shoulder belt and the dummy’s skin. The pants
should end above the dummy’s knee. The T-shirt and pants should each weigh no more than 0.14 kg (0.3
lb). Garments similar to thermal underwear (trimmed to be short-sleeved and above the knee) usually meet
these requirements. To improve the quality of high-speed films taken of the dummy during testing (by
avoiding excessive glare); the garments are usually dyed to a light pink. The shoes used with the small
adult female dummy are women’s low dress black oxfords; size 7-1/2 E that meet military specification
MIL-S-21711E. Each shoe weighs 0.41 ± 0.09 kg (.9 ± 0.2 lb). To make it easier to put the shoe on the
dummy, the shoe should be cut to extend the tongue. Talc may also be applied to the foot.

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1.5 Instrumentation
When ordering a new dummy, inform the dummy manufacturer of the type and model of accelerometer
you intend to use. This will ensure that you obtain the correct accelerometer mounts for the head, chest
and pelvis.
The following is an instrumentation list currently available for the Hybrid III 5th Female dummy.
Instrument Part Number Number of
Channels Quantity
Head Accelerometers IE-103 3 3
Upper Neck Load Cell
IF-205
6
1
IF-205J 6 1
IF-207
6
1
IF-256 4 1
IF-2564
3
1
Lower Neck Load Cell IF-211 5 1
IF-228
6
1
IF-238 6 1
Chest Accelerometers
IE-103
3
3
Sternum Accelerometers IE-103 3 3
Spine Accelerometers
IE-103
3
3
Chest Deflection: Rotary Pot 78051-342 1 1
Thoracic Spine Load Cell
IF-300
6
1
IF-302 5 1
Clavicle Load Cell
IF-353
2
1
Lumbar Spine Load Cell IF-404 5 1
IF-406
6
1
IF-429 3 1
Rib Load Cell
IF-455
4
1
Pelvis Accelerometers IE-103 3 3
ASIS Load Cells
IF-509
2
1
Femur Load Cells IF-604 2 2
IF-625
6
2
IF-628 6 2
Knee Clevis Load Cells
IF-805
2
2
Knee Sheer Displacement 880105-516 1 2
Upper Tibia Load Cells
IF-820
8
2
IF-857 5 2
Lower Tibia Load Cells
IF-819
8
2
IF-825 8 2
IF-853
5
2
Table 1.1 – Instrumentation
* The load cell part numbers listed in the table are for 350 ohm’s. 120 ohm’s load cells are also available.

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Figure 1.1 – Accelerometer Location in Dummy
ITEM
QTY
PART NO.
DESCRIPTION
1
15
IE-103
ACCELEROMETER ENDEVCO/ENTRAN 7264-2000 (REF)
2
3
H350-1005
TRIAXIAL MOUNTING BLOCK
3
1
880105-1211
HEAD ACCELEROMETER MOUNT
4
4
9000487
SCREW, SHCS #10-24 X 3/8
5
18
9000152
SCREW, SHCS #0-80 X 1/8 (REF)
6
6
9000531
SCREW, SHCS #2-56 X 5/8
7
1
H350-1006
CHEST ACCELEROMETER MOUNT
8 1
880105-1220
PELVIC ACCELEROMETER MOUNT (OPTIONAL)
1200056
PELVIC ACCELEROMETER MOUNT
9
1
9000490
SCREW, SHCS 3/8-16 X 3/4
10
4
9000624
SCREW, SHCS #10-24 X 1/2
Table 1.2- Accelerometer Location Parts List