TP201U-01

April 3, 1998

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

FMVSS 201U

Occupant Protection in Interior Impact

Upper Interior Head Impact Protection

Safety Assurance
Office of Vehicle Safety Compliance
Room 6115, NSA-30
400 Seventh Street, SW
Washington, DC 20590
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OVSC LABORATORY TEST PROCEDURE NO. 201U

TABLE OF CONTENTS
PAGE

1. PURPOSE AND APPLICATION ........................................................................................... 1

2. GENERAL REQUIREMENTS ............................................................................................... 2

3. SECURITY ............................................................................................................................ 5

4. GOOD HOUSEKEEPING ..................................................................................................... 6

5. TEST SCHEDULING AND MONITORING............................................................................ 6

6. TEST DATA DISPOSITION .................................................................................................. 6

7. GOVERNMENT FURNISHED PROPERTY (GFP) ............................................................... 6

8. CALIBRATION OF TEST INSTRUMENTS ........................................................................... 10

9. PHOTOGRAPHIC DOCUMENTATION ................................................................................ 12

10. DEFINITIONS ....................................................................................................................... 15

11. PRETEST REQUIREMENTS................................................................................................ 19

12. COMPLIANCE TEST EXECUTION ...................................................................................... 27

13. POST TEST REQUIREMENTS ............................................................................................ 68

14. REPORTS............................................................................................................................. 68

14.1. MONTHLY STATUS REPORTS ............................................................................... 68

14.2. APPARENT TEST FAILURE .................................................................................... 68

14.3. FINAL TEST REPORTS ........................................................................................... 69

14.3.1. COPIES ......................................................................................................... 69

14.3.2. REQUIREMENTS.......................................................................................... 69

14.3.3. FIRST THREE PAGES.................................................................................. 70

14.3.4. TABLE OF CONTENTS................................................................................. 75

15. DATA SHEETS ..................................................................................................................... 77

16. FORMS ................................................................................................................................. 86

APPENDIX A, P572L FREE MOTION HEADFORM CALIBRATION

APPENDIX B, FREE MOTION HEADFORM (FMH) USER'S MANUAL
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ILLUSTRATIONS
FIGURE PAGE

1 FREE MOTION HEADFORM FOREHEAD IMPACT ZONE .......................................................22

2 FMH APPROACH ANGLE COORDINATE SYSTEM .................................................................24

3 DRIVER HEAD CG FOR FRONT SEAT AFT POSITION ...........................................................31

4 REAR PASSENGER HEAD CG .................................................................................................32

5 FMH HORIZONTAL APPROACH ANGLE PLANE .....................................................................33

6 HORIZONTAL APPROACH ANGLES A1, A2, B1 & B2 .............................................................35

7 TARGET AP1 (A-PILLAR REFERENCE POINT) .......................................................................38

8 TARGET AP2..............................................................................................................................40

9 TARGET AP3..............................................................................................................................41

10 UPPER ROOF ............................................................................................................................42

11 BRP, BP1, BP2, BP3 AND BP4 ..................................................................................................46

12 BRP, BP1, BP2, BP3 AND BP4 (CONTINUED) .........................................................................46

13 OTHER PILLARS........................................................................................................................48

14 TARGET RP1..............................................................................................................................49

15 TARGET RP2..............................................................................................................................50

16 FRONT HEADER (FH1 & FH2) ..................................................................................................51

17 TOP VIEW OF SUN ROOF AND ALTERNATE FH2 ..................................................................53

18 SIDE RAIL TARGETS BETWEEN A-PILLAR AND THE B-PILLAR ...........................................54

19 OTHER SIDE RAIL TARGET POINTS (SR3) .............................................................................56

20 REAR HEADER (RH)..................................................................................................................57

21 SLIDING DOOR TRACK.............................................................................................................58

22 ROLL-BAR TARGET POINT.......................................................................................................59

23 STIFFENER TARGET.................................................................................................................60

24 ROLL-BAR, STIFFENER AND BRACE ......................................................................................61

25 VERTICAL APPROACH ANGLE PLANE....................................................................................63

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1. PURPOSE AND APPLICATION

The Office of Vehicle Safety Compliance (OVSC) provides contractor laboratories with
Laboratory Test Procedures as guidelines for obtaining compliance test data. The data
are used to determine if a specific vehicle or item of motor vehicle equipment meets the
minimum performance requirements of the subject Federal Motor Vehicle Safety
Standard (FMVSS). The purpose of the OVSC Laboratory Test Procedures is to
present a uniform testing and data recording format, and provide suggestions for the
use of specific equipment and procedures. If any contractor views any part of an OVSC
Laboratory Test Procedure to be in conflict with a Federal Motor Vehicle Safety
Standard (FMVSS) or observes deficiencies in a Laboratory Test Procedure, the
contractor is required to advise the Contracting Officer's Technical Representative
(COTR) and resolve the discrepancy prior to the start of compliance testing.

Every contractor is required to submit a detailed test procedure to the COTR before
initiating the compliance test program. The procedure must include a step-by-step
description of the methodology to be used. The contractor’s test procedure shall
contain a complete listing of test equipment with make and model number and a
detailed check-off sheet. The list of test equipment shall include instrument accuracy
and calibration dates. All equipment shall be calibrated in accordance with the
manufacturer’s instructions. There shall be no contradictions between the Laboratory
Test Procedure and the contractor’s in-house test procedure. Written approval of the in-
house test procedures shall be obtained from the COTR before initiating the compliance
test program. The OVSC Laboratory Test Procedures are not intended to limit or
restrain a contractor from developing or utilizing any testing techniques or equipment
which will assist in procuring the required compliance test data. These Laboratory Test
Procedures do not constitute an endorsement or recommendation for use of any
product or method. However, the application of any such testing technique or
equipment is subject to prior approval of the COTR.

NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose of use by
independent laboratories under contract to conduct compliance tests for the OVSC, are not
rules, regulations or NHTSA interpretations regarding the meaning of a FMVSS. The
Laboratory Test Procedures are not intended to limit the requirements of the applicable
FMVSS(s). In some cases, the OVSC Laboratory Test Procedures do not include all of the
various FMVSS minimum performance requirements. Recognizing applicable test tolerances,
the Laboratory Test Procedures may specify test conditions that are less severe than the
minimum requirements of the standard. In addition, the Laboratory Test Procedures may be
modified by the OVSC at any time without notice, and the COTR may direct or authorize
contractors to deviate from these procedures, as long as the tests are performed in a manner
consistent with the standard itself and within the scope of the contract. Laboratory Test
Procedures may not be relied upon to create any right or benefit in any person. Therefore,
compliance of a vehicle or item of motor vehicle equipment is not necessarily guaranteed if the
manufacturer limits its certification tests to those described in the OVSC Laboratory Test
Procedures.
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2. GENERAL REQUIREMENTS

FMVSS 201, Occupant Protection in Interior Impact - Upper Interior Head Impact
Protection, requires passenger cars, and trucks, buses and multipurpose passenger
vehicle's (LTV’s) with a Gross Vehicle Weight Rating (GVWR) of 4,536 kilograms or
less, except that the requirements of S6 do not apply to buses with a GVWR of 3,860
kilograms or more, to provide protection when an occupant's head strikes upper interior
components, including pillars, side rails, headers, and the roof during a crash.

Each vehicle manufactured on or after September 1, 1998, subject to the phase-in

requirements below, shall comply with the upper interior requirements of FMVSS 201 at
the target locations specified when impacted by the Free Motion Headform (FMH) at
any speed up to and including 24 kph.

PHASE-IN REQUIREMENTS - SCHEDULE #1

PERCENTAGE VEHICLE
COMPLYING MODEL YEAR PERIOD OF PRODUCTION

10% 1999 September 1, 1998 to August 31, 1999

25% 2000 September 1, 1999 to August 31, 2000
40% 2001 September 1, 2000 to August 31, 2001
70% 2002 September 1, 2001 to August 31, 2002

100% 2003 September 1, 2002 and after

ALTERNATIVE PHASE-IN REQUIREMENTS - SCHEDULE #2

PERCENTAGE VEHICLE
COMPLYING MODEL YEAR PERIOD OF PRODUCTION

7% 1999 September 1, 1998 to August 31, 1999

31% 2000 September 1, 1999 to August 31, 2000
40% 2001 September 1, 2000 to August 31, 2001
70% 2002 September 1, 2001 to August 31, 2002

100% 2003 September 1, 2002 and after

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2. GENERAL REQUIREMENTS....Continued

The phase-in percentage requirements are based on (S6.1.1, S6.1.2, S6.1.5):

A. The average annual production of passenger cars and LTV's with a GVWR of
4,536 kg or less, excluding buses with a GVWR  3,860 kg, manufactured for sale
in the United States based on three production years.

OR, at the manufacturer's option

B. The annual production of passenger cars and LTV's with a GVWR of 4,536 kg or
less, excluding buses with a GVWR  3,860 kg, manufactured for sale in the
United States for the current production year.

ALTERNATIVE PHASE-IN REQUIREMENTS - SCHEDULE #3

A manufacturer may, at its option, comply with the following:

A. Passenger cars and LTV's with a GVWR of 4,536 kg or less, excluding buses
with a GVWR  3,860 kg, manufactured before September 1, 1999, are not
required to comply with the upper interior requirements of FMVSS 201.

Then –

B. Passenger cars and LTV's with a GVWR of 4,536 kg or less, excluding buses
with a GVWR  3,860 kg, manufactured on or after September 1, 1999, shall
comply with the upper interior requirements of FMVSS 201.

ALTERNATIVE PHASE-IN REQUIREMENTS FOR FINAL STAGE

MANUFACTURERS OR ALTERERS - SCHEDULE #4

A final stage manufacturer or alterer may, at its option, comply with the following:

A. Passenger cars and LTV's with a GVWR of 4,536 kg or less, excluding buses
with a GVWR  3,860 kg, manufactured on or after September 1, 1998 and before
September 1, 2002 are not required to comply with the upper interior
requirements of FMVSS 201.

Then –

B. Passenger cars and LTV's with a GVWR of 4,536 kg or less, excluding buses
with a GVWR  3,860 kg, manufactured on or after September 1, 2002 shall
comply with the upper interior requirements of FMVSS 201.
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2. GENERAL REQUIREMENTS....Continued

PERFORMANCE REQUIREMENTS

The HIC(d) shall not exceed 1000 when calculated in accordance with the following
formula:

HIC(d) = 0.75446 (Free Motion Headform HIC) + 166.4

The Free Motion Headform HIC is calculated in accordance with the following formula:

1
t2 t1 t m
t2
HIC [ AR dt ] 2.5 t 2 t1
1

where AR= [Ax2 + A y2 + Az2]½ Resultant Acceleration magnitude in g units at the

CG of the Free Motion Headform.

t1 and t2 are any two points in time during the impact event separated by not
more than a 36 millisecond time.

AR = A 2X + A 2Y + A 2Z (Gs)
100

50
RESULTANT
ACCELERATION 0
AR , G's
-50

-100
0 .050 .100 .150
TIME AFTER IMPACT, seconds

t1 t2
FMVSS 201 REQUIREMENTS DO NOT APPLY TO (S6.3):

A. Any target located on a convertible roof frame or a convertible roof linkage

mechanism.

B. Any target located rearward of a vertical plane 600 mm behind (relative to the
vehicle orientation) the seating reference point of the rearmost designated
seating position.
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2. GENERAL REQUIREMENTS....Continued

C. Any target located rearward of a vertical plane 600 mm behind (relative to the
vehicle orientation) the seating reference point of the driver's seating position in
an ambulance or a motor home.

D. Any target in a walk-in van-type vehicle.

3. SECURITY

The contractor shall provide appropriate security measures to protect the OVSC test
vehicles from unauthorized personnel during the entire compliance testing program.
The contractor is financially responsible for any acts of theft and/or vandalism that occur
during the storage of test vehicles. Any security problem shall be reported by telephone
to the Industrial Property Manager (IPM), Office of Contracts and Procurement, within
two working days after the incident. A letter containing specific details of the security
problem will be sent to the IPM (with copy to the COTR) within 48 hours.

The contractor shall protect and segregate the data that evolves from compliance
testing before and after each vehicle test. No information concerning the vehicle safety
compliance testing program shall be released to anyone except the COTR, unless
specifically authorized by the COTR or the COTR's Branch or Division Chief. The
tested vehicles shall be protected from the elements and retained by the contractor for a
minimum of 60 days so that NHTSA personnel can be given an inspection opportunity.

NOTE: No individuals, other than contractor personnel directly involved in the

compliance testing program, shall be allowed to witness any vehicle compliance test
unless specifically authorized by the COTR. It is the contractor's responsibility to secure
the test site area during a test and to shield the test area from public view by the use of
canvas or other blocking devices.

RULES FOR CONTRACTORS

A. No vehicle manufacturer's representative(s) or anyone other than the contractor's

personnel working on the NHTSA contract program along with NHTSA personnel
shall be allowed to inspect NHTSA vehicles or witness vehicle preparation
without prior permission. Such permission shall never be assumed.

B. All communications with vehicle manufacturers shall be referred to the NHTSA.

The contractor shall not release test data without the permission of the NHTSA.
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4. GOOD HOUSEKEEPING

The contractor shall maintain the entire vehicle compliance testing area, test fixtures
and instrumentation in a neat, clean and painted condition with test instruments
arranged in an orderly manner consistent with good test laboratory housekeeping
practices.

5. TEST SCHEDULING AND MONITORING

The contractor shall submit a test schedule to the COTR prior to testing. Tests shall be
completed as required in the contract. Scheduling shall be adjusted to permit sample
motor vehicles to be tested to other FMVSS as may be required by the OVSC. All
testing shall be coordinated to allow monitoring by the COTR.

6. TEST DATA DISPOSITION

The contractor shall make all vehicle preliminary compliance test data available to the
COTR on location within four hours after the test. Final test data, including digital
printouts and computer generated plots, shall be furnished to the COTR within five
working days. Additionally, the contractor shall analyze the preliminary test results as
directed by the COTR.

All backup data sheets, strip charts, recordings, plots, technicians notes, etc., shall be
either sent to the COTR or destroyed at the conclusion of each delivery order, purchase
order, etc.

7. GOVERNMENT FURNISHED PROPERTY (GFP)

ACCEPTANCE OF TEST VEHICLES

The contractor has the responsibility of accepting test vehicles from either new car
dealers or vehicle transporters. In both instances, the contractor acts in the OVSC's
behalf when signing an acceptance of test vehicles. If a vehicle is delivered by a dealer,
the contractor must check to verify the following:

A. All options listed on the "window sticker" are present on the test vehicle.

B. Tires and wheel rims are the same as listed.

C. There are no dents or other interior or exterior flaws.

D. The vehicle has been properly prepared and is in running condition.

E. The glove box contains an owner's manual, warranty document, consumer

information, and extra set of keys.

F. Proper fuel filler cap is supplied on the test vehicle.

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7. GOVERNMENT FURNISHED PROPERTY (GFP)....Continued

If the test vehicle is delivered by a government contracted transporter, the contractor

should check for damage which may have occurred during transit.

A "Vehicle Condition" form (shown on the next page) will be supplied to the contractor
by the COTR when the test vehicle is transferred from the new car dealer or between
test contracts. The upper half of the form describes the vehicle in detail, and the lower
half provides space for a detailed description of the post test condition. Vehicle
Condition forms must be returned to the COTR with the copies of the Final Test Report
or the reports will NOT be accepted.

NOTIFICATION OF COTR

The COTR must be notified within 24 hours after a vehicle has been delivered.
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7. GOVERNMENT FURNISHED PROPERTY (GFP)....Continued

REPORT OF VEHICLE CONDITION AT THE COMPLETION OF TESTING

CONTRACT NO.: DTNH22- DATE: ___________________

FROM: ___________________________________________________________________

TO: ______________________________________________________________________

The following vehicle has been subjected to compliance testing for FMVSS No: _________________________

The vehicle was inspected upon arrival at the laboratory for the test and found to contain all of the equipment
listed below. All variances have been reported within 2 working days of vehicle arrival, by letter, to the NHTSA
Industrial Property Manager (NAD-30), with a copy to the OVSC COTR. The vehicle is again inspected, after the
above test has been conducted, and all changes are noted below. The final condition of the vehicle is also noted
in detail.

MODEL YEAR/MAKE/MODEL/BODY STYLE: ____________________________________________

NHTSA NO.: ; BODY COLOR: ; VIN: ____________________________________

ODOMETER READINGS: ARRIVAL - miles DATE - _________________________

COMPLETION - miles DATE - _________________________

PURCHASE PRICE: $ DEALER'S NAME: __________________________________________

ENGINE DATA: Cylinders ; Liters ; Cubic Inches

TRANSMISSION DATA: Automatic Manual No. of Speeds

FINAL DRIVE DATA: Rear Drive Front Drive 4 Wheel Drive

TIRE DATA: Size - Mfr. - _________________________

CHECK APPROPRIATE BOXES FOR VEHICLE EQUIPMENT:

Air Conditioning Traction Control Clock

Tinted Glass All Wheel Drive Roof Rack

Power Steering Speed Control Console

Power Windows Rear Window Defroster Driver Air Bag

Power Door Locks Sun Roof or T-Top Passenger Air Bag

Power Seat(s) Tachometer Front Disc Brakes

Power Brakes Tilt Steering Wheel Rear Disc Brakes

Antilock Brake System AM/FM/Cassette Radio Other-

LIST OTHER PERTINENT OPTIONAL EQUIPMENT ON NEXT PAGE (REMARKS SECTION)

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7. GOVERNMENT FURNISHED PROPERTY (GFP)....Continued

REMARKS:

Equipment that is no longer on the test vehicle as noted on previous page:

Explanation for equipment removal:

Test Vehicle Condition:

RECORDED BY: DATE: __________________

APPROVED BY: _____________________

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8. CALIBRATION OF TEST INSTRUMENTS

Before the contractor initiates the safety compliance test program, a test instrumentation
calibration system will be implemented and maintained in accordance with established
calibration practices. The calibration system shall be set up and maintained as follows:

A. Standards for calibrating the measuring and test equipment will be stored and
used under appropriate environmental conditions to assure their accuracy and
stability.

B. All measuring instruments and standards shall be calibrated by the contractor, or

a commercial facility, against a higher order standard at periodic intervals NOT
EXCEEDING 6 MONTHS FOR INSTRUMENTS AND 12 MONTHS FOR
CALIBRATION STANDARDS. Records, showing the calibration traceability to
the National Institute of Standards and Technology (NIST), shall be maintained
for all measuring and test equipment.

Accelerometers shall be calibrated every six months or after a vehicle fails to

meet the FMVSS 201 performance requirements whichever occurs sooner.

C. All measuring and test equipment and measuring standards will be labeled with
the following information:

(1) Date of calibration

(2) Date of next scheduled calibration

(3) Name of the technician who calibrated the equipment

D. A written calibration procedure shall be provided by the contractor including, as a

minimum, the following information for all measurement and test equipment:

(1) Type of equipment, manufacturer, model number, etc.

(2) Measurement range

(3) Accuracy

(4) Calibration interval

(5) Type of standard used to calibrate the equipment (calibration traceability

of the standard must be evident)

(6) The actual procedures and forms used to perform the calibrations.
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8. CALIBRATION OF TEST INSTRUMENTS....Continued

E. Records of calibration for all test instrumentation shall be kept by the contractor
in a manner that assures the maintenance of established calibration schedules.
All such records shall be readily available for inspection when requested by the
COTR. The calibration system will need the acceptance of the COTR before the
test program commences.

F. Test equipment shall receive a calibration adjustment immediately prior to a test

and a calibration check after the test. This check shall be recorded by the test
technician(s) and submitted with the final report.

G. The headform(s) shall be calibrated before each vehicle test and the calibration
checked after each vehicle test. A vehicle test consists of all upper interior
component targets. The contractor is required to calibrate the FMH prior to
testing the first target and subsequent to the completion of testing of all targets
on the vehicle.

When a HIC(d) greater than 1000 is recorded, the FMH must be calibrated as
soon as possible and before the continuation of compliance testing.

The pretest and post test calibrations and calibration checks shall be submitted
with the final report. A number of FMHs may be used to conduct the required
target tests. Pretest and post test calibrations must be submitted for each
headform used in the conduct of the vehicle test.

H. The contractor may be directed by NHTSA to evaluate its data acquisition

system.

Further guidance is provided in the International Standard ISO 10012-1, “Quality

Assurance Requirements for Measuring Equipment” and American National Standard
ANSI/NCSL Z540-1, “Calibration Laboratories and Measuring and Test Equipment -
General Requirements.”

NOTE: In the event of a failure to meet the standard's minimum performance

requirements additional calibration checks of some critically sensitive test equipment
and instrumentation may be required for verification of accuracy. The necessity for the
calibration will be at the COTR's discretion and will be performed without additional cost.
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9. PHOTOGRAPHIC DOCUMENTATION

Each impact test shall be documented on 16 mm color movie film at a minimum speed
of 1,000 frames-per-second. Glare or lights on any glass surface must be minimized so
that views of the FMH during the test are visible for film analysis.

A timing mark must be registered on the film edge a minimum of every 10 milliseconds
and a time zero mark must be registered on the film in order to permit test analysis on a
film analyzer. The Contractor shall report all camera locations along with camera
speeds and focal length on the appropriate final report data sheets.

CAMERA(S) REQUIRED

One camera is required for each FMH impact test. The camera should be placed
perpendicular, or as close as possible, to the plane of motion capturing the FMH free
flight and impact with the target.

IMPACT EVENT MARKER

All high speed cameras shall have film markers to mark “time zero” for the FMH impact.
REFERENCE TARGETS

Dimensional reference targets (approximately 300 mm apart) shall be placed in the

plane of motion of the FMH center of gravity (midsagittal plane). The targets orientation
within the plane is not important noting that the targets must be visible in the film image
throughout the impact event. The distance between the reference targets shall be
recorded and included in the test report.

INFORMATIONAL PLACARDS

Vehicle identification placard(s) shall be positioned so that the placard will be visible in
the camera’s field-of-view. The following information will be shown:

A. Vehicle’s NHTSA Number

B. The words “FMVSS 201U"

C. Target Identification

D. Test Date

E. Name of contract laboratory

F. Vehicle model year, make and model

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9. PHOTOGRAPHIC DOCUMENTATION....Continued

FILM TITLE AND EDITING

The 16 mm impact test movie film shall include the following frames:

A. “The following FMVSS 201U Upper Interior Impact Tests were conducted under
contract with the National Highway Traffic Safety Administration by (name and
location of test laboratory)”

B. FMVSS 201U UPPER INTERIOR IMPACT TESTS

TEST VEHICLE MODEL YEAR, MAKE AND MODEL
NHTSA No. CXXXXX
DATE CONDUCTED
CONTRACT NO.: DTNH22-XX-X-XXXXX

C. The ending frame shall state “THE END”

FILM EDITING

The film shall be edited in the following sequence:

A. Title

B. All high speed coverage in the following order:

A-Pillar Targets, B-Pillar Targets, Other Pillar Targets, Rearmost Pillar Targets,
Front Header Targets, Side Rail Targets, Rear Header Targets, Upper Roof
Target, Sliding Door Track Target, Roll-Bar Targets, Stiffener Target, and
Brace Target.

C. “THE END”

9.1 STILL PHOTOGRAPHS

Photographs shall be color, 8 x 10 inches or 8.5 x 11 inches, and legible. A tag, label or
placard identifying the test vehicle model, NHTSA number, date, and pre or post test
identification shall appear in each photograph and be legible. Each photograph shall be
labeled as to subject matter. The test setup and equipment used in all tests shall be
photographed for the record before and at prescribed time periods during testing listed
in this test procedure. Any failure must be photographed at various angles to assure
complete coverage. NOTE: Photographs of all areas of the test vehicle that may be of
importance to the upper interior impact test shall be taken in excess and developed only
if the need arises.
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9. PHOTOGRAPHIC DOCUMENTATION....Continued

As a minimum, the following photographs shall be included in the compliance report:

A. Left side view of vehicle

B. Right side view of vehicle

C. 3/4 frontal view from left side of vehicle

D. 3/4 rear view from right side of vehicle

E. Vehicle's certification label

F. Vehicle's tire information label

G. Actual instrumentation as setup for the impact test(s)

H. For each component, the pretest condition of the component with the target
location(s) marked

I. For each target, the test setup documenting the target location and FMH impact
angle

J. For each target, a post test photograph(s) documenting the target location

K. For each target, a post test photograph(s) documenting target circle contact
within the FMH forehead impact zone

L. For each component, the post test condition of the component.

9.3 REFERENCE PHOTOGRAPHIC TARGETS

The Free Motion Headform shall have targets on each side of the head with the center
of the target at the CG of the head in the X and Z direction relative to the measuring
directions of the accelerometers.

9.4 TARGET CIRCLE FOR IMPACT LOCATIONS

The areas of the vehicle to be impacted by the headform should be marked with a solid
12.7 mm diameter circle centered on the targets. Any transferable opaque medium
that identifies contact with the forehead impact zone is acceptable. Prior to the initiation
of the test program, the contractor must obtain COTR approval for the contact medium
that will be used.
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10. DEFINITIONS

A-PILLAR

Any pillar entirely forward of a transverse vertical plane passing through the seating
reference point (SgRP) of the driver's seat.

AMBULANCE

A motor vehicle designed exclusively for the purpose of emergency medical care, as
evidenced by the presence of a passenger compartment to accommodate emergency
medical personnel, one or more patients on litters or cots, and equipment and supplies
for emergency care at a location or during transport.

B-PILLAR

The forwardmost pillar on each side of the vehicle that is, in whole or part, rearward of a
transverse vertical plane passing through the SgRP of the driver's seat, unless there is
only one pillar rearward of that plane and it is also a rearmost pillar.

BRACE

A fixed diagonal structural member in an open body vehicle used to brace the roll-bar
and connect the roll-bar to the main vehicle body structure.

CONVERTIBLE

A vehicle whose A-pillars are not joined with the B-pillars (or rearmost pillars) by a fixed,
rigid structural member.

CONVERTIBLE ROOF FRAME

The frame of a convertible roof.

CONVERTIBLE ROOF FRAME LINKAGE

Any anchorage, fastener, or device necessary to deploy a convertible roof frame.

DAYLIGHT OPENING (DLO)

For openings on the side of the vehicle, other than a door opening, the locus of all
points where a horizontal line, perpendicular to the vehicle longitudinal centerline, is
tangent to the periphery of the opening.

For openings on the front and rear of the vehicle, other than a door opening, daylight
opening means the locus of all points where a horizontal line, parallel to the vehicle
longitudinal centerline is tangent to the periphery of the opening.
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10. DEFINITIONS....Continued

If a horizontal line is tangent to the periphery at more than one point at any location, the
most inboard point is used to determine the daylight opening.

DESIGNATED SEATING POSITION (DSP)

Any plan view location capable of accommodating a person at least as large as a 5th
percentile adult female, if the overall seat configuration and design and vehicle design is
such that the position is likely to be used as a seating position while the vehicle is in
motion, except for auxiliary seating accommodations such as temporary or folding jump
seats. Any bench or split-bench seat in a passenger vehicle with a GVWR less than
10,000 lb, having greater than 127 cm of hip room (measured in accordance with
SAE J1100(a)) shall have not less than three designated seating positions, unless the
seat design or vehicle design is such that the center position cannot be used for
seating.

DOOR OPENING

For door openings on the side of the vehicle, the locus of all points where a horizontal
line, perpendicular to the vehicle longitudinal centerline, is tangent to the periphery of
the side door opening.

For door openings on the back end of the vehicle, door opening means the locus of all
points where a horizontal line, parallel to the vehicle longitudinal centerline, is tangent to
the periphery of the back door opening.

If a horizontal line is tangent to the periphery at more than one point at any location, the
most inboard point is the door opening.

FOREHEAD IMPACT ZONE

The part of the Free Motion Headform surface area determined in accordance with the
procedure set forth in S8.10 and described in Section 11.4, Free Motion Headform
Forehead Impact Zone. (49CFR571.201)

FREE MOTION HEADFORM (FMH)

A test device conforming to the specifications of Part 572, Subpart L (P572L). The
P572L performance calibration procedure is included in Appendix A.

MIDSAGITTAL PLANE OF A DUMMY

A longitudinal vertical plane passing through the seating reference point (SgRP) of a
designated seating position (DSP).
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10. DEFINITIONS....Continued

MOTOR HOME

A motor vehicle with motive power designed to provide temporary residential

accommodations, as evidenced by the presence of at least four of the following
facilities: cooking; refrigeration or ice box; self-contained toilet; heating and/or air
conditioning; a potable water supply including a faucet and a sink; and a separate 110-
125 volt electrical power supply and/or an LP gas supply.

OTHER PILLAR

Any pillar that is not an A-pillar, a B-pillar, or a rearmost pillar.

PILLAR

Means any structure, excluding glazing and the vertical portion of door window frames,
but including accompanying molding, attached components such as safety belt
anchorages and coat hooks, that (1) supports either a roof or any other structure (such
as a roll-bar) above the driver's head or (2) is located along a side edge of a window.

ROLL-BAR

A fixed overhead structural member, including its vertical support structure, that extends
from the left to the right side of the passenger compartment of any open body vehicles
and convertibles. It does not include a header.

SEAT BELT ANCHORAGE

Any component involved in transferring seat belt loads to the vehicle structure,
including, but not limited to, the attachment hardware, but excluding webbing or straps,
seat frames, seat pedestals, and the vehicle structure itself, whose failure causes
separation of the belt from the vehicle structure.

SEATING REFERENCE POINT (SgRP)

Means the unique design H-point, as defined in SAE J1100 (June 1984), which:

A. Establishes the rearmost normal design driving or riding position of each

designated seating position, which includes consideration of all modes of
adjustment, horizontal, vertical, and tilt, in a vehicle;

B. Has X, Y, and Z coordinates, as defined in SAE J1100 (June 1984), established

relative to the designed vehicle structure;

C. Simulates the position of the pivot center of the human torso and thigh; and
 18
10. DEFINITIONS....Continued

D. Is the reference point employed to position the two-dimensional drafting template

with the 95th percentile leg described in SAE J826 (May 1987), or, if the drafting
template with the 95th percentile leg cannot be positioned in the seating position,
is located with the seat in its most rearward adjustment position.

SLIDING DOOR TRACK

A track structure along the upper edge of a side door opening that secures the door in
the closed position and guides the door when moving to and from the open position.

STIFFENER

A fixed overhead structural member that connects one roll-bar to another roll-bar or to a
header of any open body vehicle or convertible.

UNLOADED VEHICLE WEIGHT (UVW)

The weight of a vehicle with maximum capacity of all fluids necessary for operation of
the vehicle, but without cargo, occupants, or accessories that are ordinarily removed
from the vehicle when they are not in use.

UPPER ROOF

The area of the vehicle interior that is determined in accordance with the procedure set
forth in S8.15, Upper Roof.

WINDSHIELD TRIM

Molding of any material between the windshield glazing and the exterior roof surface,
including material that covers a part of either the windshield glazing or exterior roof
surface.
 19
11. PRETEST REQUIREMENTS

11.1 TEST DATA LOSS

A. INVALID TEST DESCRIPTION

An invalid compliance test is one that does not conform precisely to all
requirements/specifications of the OVSC Laboratory Test Procedure and
Statement of Work applicable to the test.

B. INVALID TEST NOTIFICATION

The contractor shall notify NHTSA of any test not meeting all
requirements/specifications of the OVSC Laboratory Test Procedure and
Statement of Work applicable to the test, by telephone, within 24 hours of the test
and send written notice to the COTR within 48 hours of the test completion.

C. RETEST NOTIFICATION

The Contracting Officer of NHTSA is the only NHTSA official authorized to notify
the Contractor that a retest is required. The retest shall be completed within 2
weeks after receipt of notification by the Contracting Officer that a retest is
required.

D. WAIVER OF RETEST

NHTSA, in its sole discretion, reserves the right to waive the retest requirement.
This provision shall not constitute a basis for dispute over the NHTSA's waiving
or not waiving any requirement.

E. TEST VEHICLE

NHTSA shall furnish only one vehicle for each test ordered. The contractor shall
furnish the test vehicle required for the retest. The retest vehicle shall be
equipped as the original vehicle. The original vehicle used in the invalid test shall
remain the property of NHTSA and the retest vehicle shall remain the property of
the contractor. The contractor shall retain the retest vehicle for a period not
exceeding 180 days if it fails the test. If the retest vehicle passes the test, the
contractor may dispose of it upon notification from the COTR that the test report
has been accepted.

F. TEST REPORT

No test report is required for any test that is determined to be invalid unless
NHTSA specifically decides, in writing, to require the contractor to submit such
report. The test data from the invalid test must be safeguarded until the data
from
 20
11. PRETEST REQUIREMENTS....Continued

the retest has been accepted by the COTR. The report and other required
deliverables for the retest vehicle are required to be submitted to the COTR
within 3 weeks after completion of the retest.

G. DEFAULT

The contractor is subject to the default and subsequent reprocurement costs for
non-delivery of valid or conforming test (pursuant to the Termination For Default
clause in the contract).

H. NHTSA'S RIGHTS

None of the requirements herein stated shall diminish or modify the rights of
NHTSA to determine that any test submitted by the contractor does not conform
precisely to all requirements/specifications of the OVSC Laboratory Test
Procedure and Statement of Work applicable to the test.

11.2 DETAILED TEST AND QUALITY CONTROL PROCEDURES REQUIRED

Prior to conducting any compliance test, contractors are required to submit a detailed in-
house compliance test procedure to the COTR that includes:

A. A step-by-step description of the methodology to be used.

B. A written Quality Control (QC) Procedure that shall include calibrations, the data
review process, report review, and the people assigned to performed QC on
each task.

C. A complete listing of test equipment that shall include instrument accuracy and
calibration dates as required by Section 8, Calibration of Test Instruments.

D. DETAILED checkoff lists to be used during the test and during the data
review. These lists shall include all test procedure requirements and
FMVSS requirements pertaining to the safety standard for which testing is
being performed. Each separate checkoff sheet shall identify the lab, test
date, vehicle and test technicians. These check sheets shall be used to
document that all requirements and procedures have been complied with.
These sheets shall be submitted with the test report.

There shall be no contradiction between the OVSC Laboratory Test Procedure and the
contractor's in-house test procedure. The procedures shall cover all aspects of testing
from vehicle receipt to submission of the final report. Written approval of the
procedures shall be obtained from the COTR before initiating the compliance test
program. After testing commences, written approval shall also be obtained from the
COTR prior to any changes in the procedures.
 21
11. PRETEST REQUIREMENTS....Continued

11.3 FREE MOTION HEADFORM (PART 572, SUBPART L)

The Free Motion Headform(s) used for testing must conform to the specifications of
Part 572, Subpart L (P572L). The headform must conform in every respect both before
and after being used in the vehicle test. A vehicle test consists of all upper interior
targets. The P572L performance calibration test procedure is included in Appendix A.

11.4 FREE MOTION HEADFORM FOREHEAD IMPACT ZONE

The forehead impact zone of the headform is determined in accordance with the
following procedure (S8.10):

A. Position the headform so that the baseplate of the skull is horizontal. The
midsagittal plane of the headform is designated as Plane S (Figure 1).

B. From the center of the threaded hole on top of the headform, draw a 69 mm line
forward toward the forehead, coincident with Plane S, along the contour of the
outer skin of the headform. The front end of the line is designated as Point P.

From Point P, draw a 100 mm line forward toward the forehead, coincident with
Plane S, along the contour of the outer skin of the headform. The front end of
the line is designated as Point O.

C. Draw a 125 mm line coincident with a horizontal plane along the contour of the
outer skin of the forehead from left to right through Point O so that the line is
bisected at Point O.

The end of the line on the left side of the headform is designated as Point a and
the end of the right as Point b.

D. Draw another 125 mm line, coincident with a vertical plane, along the contour of
the outer skin of the forehead through Point P so that the line is bisected at
Point P.

The end of the line on the left side of the headform is designated as Point c and
the end on the right as Point d.

E. Draw a line from Point a to Point c along the contour of the outer skin using a
flexible steel tape.

Using the same method, draw a line from Point b to Point d.

F. The forehead impact zone is the surface area on the FMH forehead bounded by
lines a-O-b and c-P-d, and a-c and b-d.
 22
11. PRETEST REQUIREMENTS....Continued

FREE MOTION HEADFORM (FMH) FOREHEAD IMPACT ZONE

MIDSAGITTAL PLANE S

FOREHEAD 125 mm
IMPACT ZONE
d c
TOP OF CENTER b a
O
OF BOLT HOLE
TOP VIEW
69 mm
MIDSAGITTAL PLANE S P
POINT P d c
100 mm c FOREHEAD
IMPACT ZONE
a b a

POINT O

SIDE VIEW FRONT VIEW

FIGURE 1

11.5 INSTRUMENTATION TO BE INSTALLED IN THE FREE MOTION HEADFORM

The contractor shall provide and install the following instrumentation in the Free Motion
Headform.

Three accelerometers shall be installed in the head cavity to measure orthogonal

accelerations (Ax, Ay, and Az) at the CG of the head assembly. The three
accelerometers shall be mounted in an orthogonal array, and the intersection of the
planes containing the sensitive axis of the 3 sensors will be the origin of the array. The
figure below illustrates the instrumentation location in the FMH. Detailed information
concerning the locations of the sensors can be found in Appendix A. The FMH shall be
instrumented with Endevco 7264-2000 accelerometers with 1% transverse sensitivity.

The contractor shall furnish data recording equipment having a sufficient number of
channels available for recording the necessary time histories. Each data channel will be
comprised of a sensor, signal conditioner, data acquisition device, and all
interconnecting cables, and must conform to the requirements of SAE Recommended
Practice J211, MAR 95 with data Class 1000 for head acceleration data.

The contractor shall provide the necessary equipment to record and display the data.
The data shall be included in the final test report and on the data tape/diskette.
 23
11. PRETEST REQUIREMENTS....Continued

FREE MOTION HEADFORM (FMH) ASSEMBLY

An instrument calibration system capable of performing individual tests on all data

channels used in acquiring the acceleration data shall conform to the appropriate
section of SAE J211 dated March 1995.

A precision time system compatible with the test equipment shall be used to provide a
time reference for all recorded data. A system/method that identifies the precise instant
of headform contact will be incorporated with the time reference signal.

An instrumentation self-checking system that simultaneously monitors all data channels

and displays, on a single indicator, will provide the GO/NO-GO status of the sensor
system.

11.6 IMPACTOR AND IMPACT CONFIGURATION

The Contractor may use any means of propelling the headform as long as the impactor
design is capable of impacting the targets specified with the FMH at 23.6 kph ± 0.3 kph
within the horizontal/vertical ranges required.

The impactor shall be able to launch the headform from any location inside the vehicle
within specified approach angles. At the time of launch, the midsagittal plane of the
headform is vertical and upright.
 24
11. PRETEST REQUIREMENTS....Continued

The headform travels freely through the air, along a velocity vector perpendicular to the
headform's skull cap plate, not less than 25 mm before making contact with the vehicle
target (S8.13.2). The FMH shall travel in free flight at least 25 mm prior to impact.

The forehead impact zone (some portion of) shall contact the target circle (some portion
of) at the time of initial contact (S8.13.3).

NOTE: If the forehead impact zone fails to make initial contact with any part of the
target circle, the OVSC considers that an incomplete test for the purpose of evaluating
that target to the requirements of FMVSS 201.

11.7 ORTHOGONAL REFERENCE SYSTEM

An orthogonal reference system consisting of a longitudinal X-axis and a transverse Y-

axis in the same horizontal plane and a vertical Z-axis through the intersection of X and
Y defines the headform's horizontal direction of approach. Figure 2 illustrates the
horizontal approach angle coordinate system. The X-Z plane is the vertical longitudinal
zero plane and is parallel to the vehicle's longitudinal centerline. The X-Y plane is the
horizontal zero plane parallel to the ground. The Y-Z plane is the vertical transverse
zero plane that is perpendicular to the X-Y and X-Z planes. The X coordinate is
negative forward of the Y-Z plane and positive to the rear. The Y coordinate is negative
to the left of the X-Z plane and positive to the right. The Z coordinate is negative below
the X-Y plane and positive above it.
FMH APPROACH ANGLE COORDINATE SYSTEM
+Z

PARALLEL TO THE
VEHICLE'S
-X LONGITUDINAL AXIS

+Y

-Y

+X

REAR OF
-Z VEHICLE
 25

11. PRETEST REQUIREMENTS....Continued

11.8 TEST TEMPERATURE CONDITIONS

The Contractor must verify that the FMH temperature is in the specified temperature
range of 19ºC to 26ºC at any relative humidity between 10 percent to 70 percent. The
FMH must be soaked in an ambient air environment in the specified range for a
minimum of 4 hours prior to the test.

The ambient air temperature must be monitored and continuously recorded within
1 meter of the headform. The temperature sensors shall be accurate at least to within
± 0.1ºC.

The contractor shall mark the ambient air temperature recording with the date, time and
technician's name at the beginning of the 4 hour soak and when the test commences.
Temperature recordings shall be furnished to the COTR with final test reports.

11.9 FMH IMPACT SPEED MEASUREMENT

The impact speed will be determined by integrating the Free Motion Headform X-axis
acceleration. The contractor will process the acceleration versus time data recorded
from the headform X-axis accelerometer to obtain the headform velocity data.

11.10 TEST DATA ACQUISITION AND REDUCTION

Analog data is prefiltered (Class 1000) and digitized at a minimum rate of

10,000 samples per second. The data is then placed into permanent storage on a
magnetic disk or tape after application of appropriate calibration scale factors.

As the data is recalled for integration or plotting, the appropriate filter is applied. The
filters are in accordance with SAE Recommended Practice J211 dated March 1995,
"Instrumentation for Impact Tests." Velocity and displacement data is plotted after
application of an SAE Class 180 filter.

Before plotting, the contractor's program manager or engineer shall determine the "time
zero". When a velocity or displacement trace is to be plotted, integration for the
appropriate acceleration signal is performed digitally.
 26
11. PRETEST REQUIREMENTS....Continued

The filtering requirements for FMH data is Class 1000. As stated previously, the
minimum sampling rate requirement is 10,000 samples per second per channel.
NOTE: The contractor must meet all the requirements in the NHTSA "Data Tape
Reference Guide" which is available from the following organization:

U.S. Department of Transportation

National Highway Traffic Safety Administration
Office of Crashworthiness Research
Safety Systems Engineering and Analysis Division
Mail Code: NRD-11
400 Seventh Street, SW
Washington DC 20590
Telephone: 202-366-4850

NHTSA’s “Data Tape Reference Guide” is also available from the agency’s web site
www.nhtsa.dot.gov

ALGORITHMS USED TO CALCULATE THE HEAD INJURY CRITERION (HIC) AND

TO DIGITALLY FILTER THE CLASS 1000 DATA

Information for the FORTRAN algorithms used to calculate the HIC and digitally filter the
Class 1000 data collected from the FMH impact tests is available from the NHTSA
Internet website. A listing of the variables required by the furnished algorithms shall
also be supplied to the contractor.

For the various filter classes, the following cut-off frequencies shall be required:

CLASS CUT-OFF FREQUENCY

60 100
180 300
600 1000

1000 1650

The most recent versions of the algorithms can be obtained from the agency’s web site
identified above. Any questions pertaining to the algorithms or requests for the
algorithms should be directed to the organization identified above.

If a contractor is not presently certified as defined by the "Data Tape Reference Guide,"
the same organization should be contacted. A contractor is not considered qualified for
test work described herein without this certification.