Humanetics Q10 2020 User manual

HUMANETICS
23300 HAGGERTY ROAD
FARMINGTON HILLS, MICHIGAN 48335 USA
012-9900 Q10 2020
USER MANUAL [Rev. 1]
Q10 2020
10.5 YEAR
OLD CHILD
012-0000

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Our Vision
Global leadership in occupant safety test & measurement
for the development of safer vehicles, ulmately saving lives.
Our Mission
To achieve our vision and increase enterprise value,
our customer focused organizaon will:
»Aract and develop exceponal people
»Reduce performance variability of our products,
systems, and services
» Connuously improve and innovate our products
and services
» Invent the next generaon of test & measurement
products by facilitang the cooperaon of industry,
regulators, government, and academic instuons
» Exceed our customer’s expectaons of reliability,
support, dependability and innovaon
» Achieve supply chain and manufacturing excellence

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Company & Support
Humanecs is the world’s leading supplier in the design and manufacture of sophiscated crash
test dummies, associated technical support and laboratory services, development and supply of
nite element soware dummy models for computerized crash test simulaons and speciales
in stac and dynamic strain measurements.
Humanecs is the only full service provider worldwide oering on and o-site customer
laboratory management service, training and consultancy. In addion, Humanecs’ local oces
and agents are capable of providing full technical support on both the physical and virtual product
lines. Humanecs also has an Engineer to Order capability, catering to specic customer needs.
Humanecs also designs and manufactures all applicable load cells in the crash safety area,
ranging from single axis low-weight seat belt to mul-axis heavy duty crash wall load cells.
Calibraon Laboratories
Crash Wall Load Cells
Dummy Load Cells
Engineer to Order Products
Localized Technical Support
Users Training
Spare Parts Management

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General Safety Instrucons
Non compliance with these general safety instrucons can endanger the safety of humans
(including death or serious injury), the environment and the equipment. This can lead to loss of
any claims to compensaon for damages.
The safety instrucons in this manual are structured and dened as follows:
WARNING
TYPE AND SOURCE OF DANGER
Refers to an immediately dangerous
situation, which may lead to death or serious
injury.
DANGER
TYPE AND SOURCE OF DANGER
Refers to an immediately dangerous
situation, which may lead to death or serious
injury.
DANGER
FATAL INJURY BY ELECTRIC SHOCK
There is a risk of electric shock when
connecng the device to the power supply.
Finding and removing faults on electrical
components, cables, and connecons may lead
to accidents, including electrocuon. All work
on electrical connecons must only be carried
out by a qualied electrician in accordance
with technical electrical regulaons.
DANGER
RISK OF FATAL INJURY
The operator must ensure that the test device
is completely visible from the operator’s desk.
DANGER
RISK OF INJURIES CAUSED BY NOISE, FIRE,
AND FLYING DEBRIS
The operator must ensure that personnel
are protected against risks caused by the
test set-up/procedure, for example, noise
and re risks or risks of injury as a result of
ying debris.
DANGER
SUBSTANCE RISKS
The operator must ensure that personnel are
protected from material/substance hazards
caused by the test set-up and procedure.
DANGER
RISK OF INJURY
There is a risk of injury due to the toppling
and slipping of the device. Install the device
on a industrial concrete oor with a minimum
thickness of 15 cm. Posion the device in the
locaon specied and secure with suitable
fastening bolts.
CAUTION
TYPE AND SOURCE OF DANGER
Refers to an immediately dangerous
situation, which may lead to minor injuries or
material damage if not prevented.
NOTICE
Indicates useful tips, recommendations
and information for an improved or more
efficient and trouble-free operation.
Safety Symbols & Description

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Addional safety symbols and descripons:
WARNING
EXPLOSION
Refers to the risks and dangers
of explosion.
WARNING
HAND INJURIES
Refers to the risks and dangers
of hand injuries.
WARNING
HOT SURFACES
Refers to the risks and dangers of injury
from hot surfaces.
WARNING
HIGH VOLTAGE
Refers to the risks and dangers of electric
shock, possibly with fatal consequences.
WARNING
CORROSIVE
Refers to the risks and dangers
of corrosion.
WARNING
ENTRAPMENT
Refers to the risks and dangers
of entrapment.
WARNING
OVERHEAD CRANE
Refers to the risks and dangers of lied
loads that can fall down or injure people.
WARNING
WEAR EYE PROTECTION
Refers to a potenally dangerous situaon,
which may lead to death or serious injury if
not prevented.
WARNING
WEAR HAND PROTECTION
Refers to a potenally dangerous situaon,
which may lead to death or serious injury if
not prevented.
WARNING
READ INSTRUCTION MANUAL
Refers to a potenally dangerous situaon,
which may lead to death or serious injury if
not prevented.
WARNING
WEAR FOOT PROTECTION
Refers to a potenally dangerous situaon,
which may lead to death or serious injury if
not prevented.
Safety Symbols & Description

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Table of Contents
Table of Contents�������������������������������������������������������������������������������������������������������������� vii
List of Figures�������������������������������������������������������������������������������������������������������������������� xiv
List of Tables��������������������������������������������������������������������������������������������������������������������� xvii
SECTION 1
Introduction ������������������������������������������������������������������������������������������������������������������������� 1
1.1 Q10 2020 Introduction .............................................................................................................................. 1
1.1.1 Development History ............................................................................................................................2
1.1.2 Application ............................................................................................................................................2
1.1.3 Standard Dummy Delivery ....................................................................................................................2
1.2 Getting Familiar with the User Manual ............................................................................................... 2
1.2.1 Section Organization .............................................................................................................................3
1.2.2 Conventions Used throughout this Manual .........................................................................................3
SECTION 2
Dummy Preparation and Use ������������������������������������������������������������������������������������������ 5
2.1 General ................................................................................................................................................ 5
2.1.1 Hardware and Fasteners .......................................................................................................................5
2.1.2 Recommended Tools .............................................................................................................................5
2.1.3 Torque Values ........................................................................................................................................6
SECTION 3
Top Level Dummy Assembly �������������������������������������������������������������������������������������������� 7
3.1 Description of Features ....................................................................................................................... 7
3.2 Assembly of Top Level ......................................................................................................................... 7
3.2.1 Top Level Parts List ................................................................................................................................7
3.3 Disassembly of Body Segments ........................................................................................................... 9
3.3.1 Suit Disassembly ....................................................................................................................................9
3.3.2 Head/Neck Disassembly ......................................................................................................................10
3.3.3 Neck/Torso Disassembly .....................................................................................................................12
3.3.4 Torso Disassembly ...............................................................................................................................13
3.3.5 Arm Disassembly .................................................................................................................................13
3.3.6 Lumbar Disassembly ...........................................................................................................................14
3.3.7 Pelvis Disassembly ...............................................................................................................................15
3.3.8 Leg Disassembly ..................................................................................................................................15
Table of Contents

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Table of Contents
SECTION 4
Head Assembly ������������������������������������������������������������������������������������������������������������������ 16
4.1 Description of Features ..................................................................................................................... 16
4.2 Assembly of Head .............................................................................................................................. 16
4.2.1 Head Assembly Parts List ....................................................................................................................16
4.2.2 Assembly of Head Components .........................................................................................................17
SECTION 5
Neck Assembly������������������������������������������������������������������������������������������������������������������� 20
5.1 Description of Neck Assembly and Features .................................................................................... 20
5.2 Assembly of the Neck ........................................................................................................................ 20
5.2.1 Neck Assembly Parts List ....................................................................................................................20
5.2.2 Assembly of Neck Components ..........................................................................................................21
SECTION 6
Thorax Assembly��������������������������������������������������������������������������������������������������������������� 22
6.1 Description of Thorax Assembly and Features ................................................................................. 22
6.2 Assembly of the Thorax ..................................................................................................................... 22
6.2.1 Thorax Assembly Parts List .................................................................................................................22
6.2.2 Assembly of Thorax Components .......................................................................................................23
SECTION 7
Arm Assembly�������������������������������������������������������������������������������������������������������������������� 26
7.1 Description of Lower Arm and Hand Assembly and Features ......................................................... 26
7.2 Assembly of the Arm ......................................................................................................................... 26
7.2.1 Arm Assembly Parts List .....................................................................................................................26
7.2.2 Assembly of the Arm Components .....................................................................................................29
SECTION 8
Lumbar Assembly�������������������������������������������������������������������������������������������������������������� 31
8.1 Description of Lumbar Assembly ...................................................................................................... 31
8.2 Assembly of the Lumbar .................................................................................................................... 31
8.2.1 Lumbar Assembly Parts List ................................................................................................................31
8.2.2 Assembly of the Lumbar assembly Components ...............................................................................32

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Table of Contents
SECTION 9
Pelvis Assembly����������������������������������������������������������������������������������������������������������������� 33
9.1 Description of Pelvis Assembly.......................................................................................................... 33
9.2 Assembly of the Pelvis ....................................................................................................................... 33
9.2.1 Pelvis Assembly Parts List ...................................................................................................................33
9.2.2 Assembly of the Pelvis assembly Components ..................................................................................35
SECTION 10
Leg Assembly���������������������������������������������������������������������������������������������������������������������� 40
10.1 Description of Leg Assembly ............................................................................................................. 40
10.2 Assembly of the Leg .......................................................................................................................... 40
10.2.1 Leg Assembly Parts List .......................................................................................................................40
10.2.2 Assembly of the Leg Components ......................................................................................................44
10.2.3 Assembly of the Upper leg to the Pelvis .............................................................................................45
SECTION 11
Dummy Suit and Hip Shield ������������������������������������������������������������������������������������������� 46
11.1 Description of the Suit and Hip Shield Features ............................................................................... 46
11.2 Assembly of the Suit .......................................................................................................................... 46
11.2.1 Suit Parts List .......................................................................................................................................46
11.2.2 Assembly of Suit ..................................................................................................................................46
11.3 Assembly of the Hip Shields .............................................................................................................. 47
SECTION 12
Instrumentation ���������������������������������������������������������������������������������������������������������������� 48
12.1 General .............................................................................................................................................. 48
12.2 Transducers ....................................................................................................................................... 48
12.3 Accelerometers Mounts ................................................................................................................... 50
12.4 Cable Routing .................................................................................................................................... 54
12.5 Abdomen Pressure Twin Sensor (APTS) ............................................................................................ 55
12.5.1 Purpose ................................................................................................................................................55
12.5.2 Description ..........................................................................................................................................55
SECTION 13
Pretest Checks ������������������������������������������������������������������������������������������������������������������� 57
13.1 Recommended Spare Parts ............................................................................................................... 59

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Table of Contents
SECTION 14
Certification Equipment�������������������������������������������������������������������������������������������������� 60
14.1 Requirements .................................................................................................................................... 60
14.2 Equipment ......................................................................................................................................... 60
14.2.1 Head Drop ..........................................................................................................................................60
14.2.2 Neck and Lumbar Spine ......................................................................................................................61
14.2.3 Full Body Pendulum ............................................................................................................................63
14.2.4 Abdomen Test Rig ...............................................................................................................................64
14.3 Equipment List ................................................................................................................................... 65
SECTION 15
Certification Procedures������������������������������������������������������������������������������������������������� 68
15.1 Head Certification ............................................................................................................................. 68
15.1.1 General ................................................................................................................................................68
15.1.2 Instrumentation ..................................................................................................................................68
15.2 Frontal Impact Head Certification..................................................................................................... 68
15.2.1 Test Procedure ....................................................................................................................................68
15.2.2 Data Processing ...................................................................................................................................69
15.2.3 Requirement ........................................................................................................................................69
15.3 Lateral Impact Head Certification ..................................................................................................... 70
15.3.1 Test Procedure ....................................................................................................................................70
15.3.2 Data Processing ...................................................................................................................................71
15.3.3 Requirement ........................................................................................................................................71
15.4 Neck Certification .............................................................................................................................. 71
15.4.1 General ................................................................................................................................................71
15.5 Flexion Neck Test ............................................................................................................................. 72
15.5.1 Set-up ..................................................................................................................................................72
15.5.2 Performing the Test ............................................................................................................................73
15.5.3 Data Processing ...................................................................................................................................73
15.5.4 Requirements ......................................................................................................................................73
15.6 Extension Neck Test ..........................................................................................................................74
15.6.1 Set-up ..................................................................................................................................................74
15.6.2 Performing the Test ............................................................................................................................75
15.6.3 Data Processing ...................................................................................................................................75
15.6.4 Requirements ......................................................................................................................................75