ISO 15830-4:2005

INTERNATIONAL ISO
STANDARD 15830-4
First edition
2005-12-01
Road vehicles — Design and
performance specifications for
the WorldSID 50th percentile male
side-impact dummy —
Part 4:
User's manual
Véhicules routiers — Conception et spécifications de performance pour
e
le mannequin mondial (WorldSID), 50 percentile homme, de choc
latéral —
Partie 4: Manuel de l'utilisateur

Reference number
©
ISO 2005
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©  ISO 2005
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Published in Switzerland
ii © ISO 2005 – All rights reserved

Contents Page
Foreword.xi
Introduction.xii
1 Scope.1
2 Normative references.1
3 Terms and definitions .1
4 Requirements.2
4.1 Disassembly and assembly.2
4.2 Full arm changeover.2
Annex A (normative) Procedures for disassembling and assembling the WorldSID.3
A.1 Head.3
A.1.1 Parts list for head .3
A.1.2 Disassembling .5
A.1.3 Assembling.6
A.1.4 Instrumentation mounting .7
A.2 Neck.8
A.2.1 Parts lists for neck.8
A.2.2 Disassembling .10
A.2.3 Assembling.12
A.2.4 Instrumentation mounting .14
A.3 Thorax, abdomen and shoulder .14
A.3.1 Parts list.14
A.3.2 Disassembling .20
A.3.3 Assembling.27
A.3.4 Instrumentation mounting .32
A.4 Full arm.35
A.4.1 Parts list.35
A.4.2 Disassembling .42
A.4.3 Assembling the arm .44
A.4.4 Adjusting the arm .46
A.4.5 Changing full arm from left to right side impact .49
A.5 Half arm.50
A.5.1 Parts list for half arm.50
A.5.2 Disassembling .51
A.5.3 Assembling.51
A.6 Pelvis.52
A.6.1 Parts list for pelvis.52
A.6.2 Disassembling .57
A.6.3 Assembling the pelvis.66
A.6.4 Instrumentation mounting .67
A.7 Full leg assembly.67
A.7.1 Parts list.67
A.7.2 Disassembling .74
A.7.3 Assembling the leg.76
A.7.4 Adjusting the leg.80
A.8 Suit assembly.82
A.8.1 Parts list for suit .82
A.8.2 Disassembly.82
A.8.3 Assembly.82
Annex B (informative) Overview of an example permissible internal data acquisition system.83
B.1 General.83
B.2 System components.83
B.2.1 G5 module.84
B.2.2 G5 docking station.84
B.2.3 G5-DB.84
B.2.4 Docking station to G5-DB cable.84
B.2.5 In-dummy battery and cable .86
B.2.6 G5-DB to battery and temperature sensor cable.86
B.2.7 G5-DB to dummy exit cable .86
B.2.8 Dummy exit to TDAS status box cable.86
B.2.9 TDAS status box .86
B.2.10 DC/DC converter .87
B.2.11 AC/DC converter .87
B.2.12 TDAS power supply.87
B.2.13 TDAS software .87
B.2.14 Status box to PC cable.87
B.2.15 Notebook PC .87
B.3 Dummy exit to status box cable pinout.88
B.4 Sensor cable length.89
Annex C (normative) Fastener torque values .91
Annex D (informative) Fastener abbreviations and ISO references for user convenience .92
Annex E (informative) Recommended WorldSID general practices .93
E.1 Certification test intervals.93
E.2 Recommended inspection practices .93
E.3 WorldSID thorax half width.94
E.4 Avoiding possible connector damage.94
E.5 Temperature range .94
E.6 Dummy handling.94
E.6.1 General.94
E.6.2 Procedures for using the lifting bracket are as follows .95
E.7 Dummy storage.95
Annex F (informative) Recommended WorldSID seating procedure .96
F.1 Placement procedures for the driver seat position.96
F.1.1 General.96
F.1.2 Electronic spreadsheets .96
F.2 Placement procedures for the rear seat position.96
F.2.1 ATD preparation.96
F.2.2 Position the seat .96
F.2.3 Dummy placement.96
Annex G (informative) Suggested WorldSID wiring procedures.98
G.1 Head wiring.98
G.2 Neck.98
st
G.3 Shoulder rib and 1 thorax rib .99
nd rd
G.4 2 and 3 Thorax ribs and abdomen ribs .100
G.5 Pelvis cable routing.100
G.6 Installation of sensor connectors to the thorax connector station.101
G.7 Instrumented arm cable routing.107
G.7.1 General considerations.107
G.7.2 Lower arm cables.107
G.7.3 Upper arm cables.108
G.7.4 Elbow cables.108
G.7.5 Routing wires through flesh component .109
G.8 Instrumented leg cable routing .110
G.8.1 Lower leg cable routing .110
G.8.2 Knee cable routing.111
G.8.3 Femoral neck cable routing.112
G.9 Wiring with an external DAS.113
iv © ISO 2005 – All rights reserved

Annex H (informative) WorldSID temperature information.114
H.1 Temperature sensitivity of WorldSID.114
H.2 Monitoring of temperature variations of WorldSID .114
H.3 Effect of internal DAS on dummy temperature.115
H.4 Practical notes for full body testing related to temperature .115
Annex I (normative) Recommended WorldSID grounding scheme.116
I.1 Parts list.116
I.2 Grounding procedures.116

Figures
Figure A.1 — WorldSID head components .4
Figure A.2 — Removal of moulded head .5
Figure A.3 — Separating the head core from the neck .5
Figure A.4 — Removing upper neck load cell from instrumented head core.6
Figure A.5 — Wire routing for head instrumentation .7
Figure A.6 — WorldSID head instrumentation .8
Figure A.7 — WorldSID neck components.9
Figure A.8 — Removing lower neck bracket .10
Figure A.9 — Removing upper neck bracket.10
Figure A.10 — Using clamp to remove neck interface plate .11
Figure A.11 — Neck dampers are free to be removed when interface plates are removed .11
Figure A.12 — Lateral positions for neck buffers .12
Figure A.13 — Assembling of neck buffers .13
Figure A.14 — Neck triaxial accelerometer installation.14
Figure A.15 — Components of WorldSID thorax and abdomen .17
Figure A.16 — Shoulder .18
Figure A.17 — WorldSID spine box assembly .20
Figure A.18 — Removing shoulder load cell assembly.21
Figure A.19 — Detaching shoulder rib at front from sternum.22
Figure A.20 — Detaching the rib from the spine box at the rear.22
Figure A.21 — Battery assembly.24
Figure A.22 — Internal spine box assembly.25
Figure A.23 — Angular accelerometer assembling.26
Figure A.24 — IR-TRACC ball joint assemblies are mounted to the struck-side plate of the spine box.27
Figure A.25 — Shoulder rib is grey, the first thoracic rib is red, and the second and third thoracic ribs and
abdominal ribs are white.28
Figure A.26 — Components of thorax rib .29
Figure A.27 — Wire routing for rib instrumentation .30
Figure A.28 — Plugging rib instrumentation cables into the front of the G5 modules mounted in the spine box .30
Figure A.29 — The rib and abdominal couplers are attached to the ribs after instrumentation is plugged in.31
Figure A.30 — Installation of G5 modules.32
Figure A.31 — WorldSID rib instrumentation.33
Figure A.32 — G5 DAS module.34
Figure A.33 — Interposer connector.34
Figure A.34 — DAS connector .34
Figure A.35 — Arrangement of DAS, interposer connector, and connector .35
Figure A.36 — Full arm, exploded.37
Figure A.37 — Shoulder-arm detail .38
Figure A.38 — Upper arm, exploded.39
Figure A.39 — Elbow section .40
Figure A.40 — Lower arm, exploded.41
Figure A.41 — Wrist.42
Figure A.42 — 'Z' Pivot and upper arm tube.43
Figure A.43 — Elbow potentiometer.45
Figure A.44 — Elbow potentiometer wiring .45
Figure A.45 — Arm joint rotation .46
Figure A.46 — Arm joint tension points .47
Figure A.47 — Elbow adjustment .48
Figure A.48 — Elbow friction adjustment.49
Figure A.49 — Change-over components .50
Figure A.50 — Arm assembly.51
Figure A.51 — WorldSID pelvis components .54
Figure A.52 — Rear view of pelvis assembly .55
vi © ISO 2005 – All rights reserved

Figure A.53 — Front view of pelvis assembly .55
Figure A.54 — Close-up view of pubic assembly.56
Figure A.55 — Close-up view of lumbar assembly.56
Figure A.56 — Removing spine box from the pelvis .57
Figure A.57 — Detaching the femur assemblies.58
Figure A.58 — Pelvis flesh .59
Figure A.59 — Removing sacroiliac backing plates to separate the pelvic bone-pubis assembly .59
Figure A.60 — Separating moulded pelvis bone from pubis assembly.60
Figure A.61 — Separating pubic buffers from pubic load cell structural replacement .60
Figure A.62 — Detaching the lumbar spine.61
Figure A.63 — Separating the upper lumbar clamping plate and lumbar mounting wedge from the lumbar spine.61
Figure A.64 — Removing the lower lumbar mounting bracket weldment .62
Figure A.65 — Removing the sacroiliac load cell interface .62
Figure A.66 — Removing pelvis instrumentation cover plate.63
Figure A.67 — Removing the pelvis instrumentation bracket .63
Figure A.68 — Removing the DAS cover .64
Figure A.69 — Removing the docking station .64
Figure A.70 — Removing interposer mass replacement.65
Figure A.71 — Separating the sacroiliac and lumbar spine load cell structural replacements .65
Figure A.72 — Routing of wires for pelvis instrumentation .67
Figure A.73 — Femoral neck.68
Figure A.74 — Upper leg assembly.69
Figure A.75 — Knee .70
Figure A.76 — Lower leg tube assembly.71
Figure A.77 — Foot and ankle.72
Figure A.78 — Ankle assembly .73
Figure A.79 — Ankle.75
Figure A.80 — Knee assembling.76
Figure A.81 — Knee potentiometer wiring.77
Figure A.82 — Knee potentiometer installation.77
Figure A.83 — Torquing the knee contact load cell.78
Figure A.84 — Ankle potentiometer wiring .79
Figure A.85 — 'X' and 'Y' version assembling .79
Figure A.86 — Ankle assembly potentiometers .80
Figure A.87 — Knee assembly .81
Figure A.88 — Leg joint adjustments.81
Figure A.89 — Ankle adjustment.82
Figure B.1 — WorldSID G5 DAS system diagram .85
Figure B.2 — Dummy exit to TDAS status box cable 2B 14-pin lemo connector wiring side view sockets.88
Figure B.3 — Dummy exit to TDAS status box cable 2B 19-pin lemo connector, wiring side view, pins .89
Figure E.1 — Lifting bracket assembly.95
Figure G.1 — Cable routing for the head.98
Figure G.2 — WorldSID neck cable routing.99
Figure G.3 — IR-TRACC and linear accelerometer routing for shoulder and 1st thorax ribs .99
Figure G.4 — Cable routing for IR-TRACC and linear triax accelerometers of the 2nd, 3rd thorax ribs and abdomen
ribs . 100
Figure G.5 — Pelvis cable routing. 101
Figure G.6 — Installations of sensor connectors to the thorax connector station. 101
Figure G.7 — Cable routing for the thorax connector station. 103
Figure G.8 — Thorax cable routing . 104
Figure G.9 — Shoulder area final cable routing . 104
Figure G.10 — Pelvis cable and dummy exit cable routing. 105
Figure G.11 — Thorax cable routing . 105
Figure G.12 — DAS exit cable and tilt sensor cables. 106
Figure G.13 — Shoulder load cell cable rounting. 106
Figure G.14 — WorldSID final dummy wiring. 107
Figure G.15 — Lower arm cables. 108
Figure G.16 — Upper arm cables. 108
Figure G.17 — Cables in the elbow region. 109
Figure G.18 — Lower arm flesh. 109
viii © ISO 2005 – All rights reserved

Figure G.19 — Upper arm flesh.110
Figure G.20 — Lower arm suit.110
Figure G.21 — Lower leg cables .111
Figure G.22 — Knee area cable routing.111
Figure G.23 — Knee area cable routing.112
Figure G.24 — Knee area cable routing and flesh .112
Figure G.25 — Femoral neck cable routing.113
Figure H.1 — Location of temperature sensors used for internal temperature survey .114
Figure I.1 — Cable attachment to the upper neck load cell .116
Figure I.2 — Spine box cable routing .117
Figure I.3 — Spine box cable attachment .117
Figure I.4 — Spine box cable attachment .118
Figure I.5 — Lumbar cable attachment .118
Figure I.6 — Pelvic load cell cable attachment.119
Figure I.7 — Knee cable attachment .119
Figure I.8 — Cable attachment.120
Figure I.9 — Tibia cable attachment.120

Tables
Table A.1 — Parts list for WorldSID head .3
Table A.2 — Parts list for WorldSID neck.8
Table A.3 — Parts list for the WorldSID thorax, abdomen and shoulder .15
Table A.4 — Parts list for shoulder assembly.18
Table A.5 — Parts list for WorldSID spine box.19
Table A.6 — Parts list for full arm.36
Table A.7 — Parts list for shoulder-arm .37
Table A.8 — Parts for upper arm.38
Table A.9 — Parts list for elbow .39
Table A.10 — Parts for lower arm .40
Table A.11 — Parts list for wrist .41
Table A.12 — Parts list for WorldSID .50
Table A.13 — Parts list for WorldSID pelvis .52
Table A.14 — Parts list for femoral neck (W50-51034).68
Table A.15 — Parts for upper leg .68
Table A.16 — Parts list for knee .69
Table A.17 — Parts list for lower leg tube .70
Table A.18 — Parts list for ankle-foot.71
Table A.19 — Parts list for ankle .72
Table B.1 — WorldSID G5 DAS parts list.83
Table B.2 — Dummy exit to status box cable pinout.88
Table B.3 — Example instrumentation cable lengths.89
Table C.1 — Screw torques.91
Table D.1 — Summary of fasteners abbreviations, descriptions and ISO references .92
Table E.1 — Parts list for lifting bracket assembly .94
Table H.1 — Effect of internal and external DAS on WorldSID internal air temperature . 115
Table I.1 — List of ground cables. 116

x © ISO 2005 – All rights reserv
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