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August 2009
Welcome to MGA Research Corporation
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Featured Article...
"Robot-crobatics" at MGA
David Powers, Troy, MI
(david.powers@mgaresearch.com)
 Robot Area
MGA already has a reputation in the automotive seating industry for the quality and versatility of its Ingress/Egress (I/E) testing. Robot driven I/E testing is predominantly used for evaluating the durability characteristics of seats when an occupant enters or exits a vehicle; specifically, how the trim material on the seats is affected by the robot path.

Testing with robots is beneficial because it provides a repeatable setup while simulating realistic usage situations. The robots operate on six axes, and have a range of movement that can accurately reproduce that of an actual person. Pressure mapping is used to examine the load and path characteristics of an actual person sitting down and getting up off of a seat. These profiles can even be taken off-site to accommodate customer needs. The information from the pressure mapping is then used to create an identical path for the buttocks form to follow when tested with the robot. A load cell attached to the wrist of the robot allows for the precise application of loads prescribed for the test. As cushions soften, the robot will adjust its path in order to match the prescribed loads while maintaining the programmed path. 
 
South Carolina Expansion
Jennifer Hill - Greer, SC(jennifer.hill@mgaresearch.com) 
 
FMVSS 209Now that MGA has been established in South Carolina for almost a year, the time has come to enhance our testing scope. We recently had our A2LA renewal assessment, and have added a variety of testing capabilities to complement our laboratory. Critical to the aerospace industry, we added Head Injury Criteria (HIC) delethalization impact testing, which is specific to FAR 25.785 for testing airline seats. We have also added a variety of Federal Motor Vehicle Safety Standards (FMVSS) to our menu of test methods.
 
For seat belt webbing and hardware:
 - FMVSS 209 Seat Belt Assemblies
 - FMVSS 213 Child Restraint Systems

For seat, seat belt, and child anchorage systems:
 - FMVSS 207 Seating Systems
 - FMVSS 210 Seat Belt Assembly Anchorages
 - FMVSS 225 Child Restraint Anchorage

For doors locks and hinges:
 - FMVSS 206 Door Locks and Door Retention Components 

We have also expanded our material testing capabilities in order to support plastic manufacturers. As for new equipment to the facility, we have added a durometer hardness tester, an additional Universal Testing Machine (UTM), Izod/Charpy Impactor, a Vertical Flammability chamber (which complements our existing horizontal chamber), and Melt Flow (extrusion plastometer). Specifications have been added to the thread testing scope, as well as several methods to be used with the current UTMs. The materials lab now encompasses plastics, foams, threads, and fabric testing.

For more information regarding our South Carolina facility and any questions or comments, call Natalee Ramsden
(natalee.ramsden@mgaresearch.com) or Jennifer Hill (jennifer.hill@mgaresearch.com) at (864) 848-3088.
MGA Presents the FMVSS 201U FMH Webinar on Thursday, August 20th
DJ Whiteside - Troy, MI
(dj.whiteside@mgaresearch.com)
 
MGA would like to invite you to participate in its first ever technical webinar on the topic of FMVSS 201U free motion headform (FMH) testing for final-stage and altered vehicles. The event is scheduled for Thursday, August 20th, from 2 to 3 pm, and will take place via the internet using GoToWebinar.com. There is no cost to participate. 

FMH ImpactThe webinar will focus on the upcoming FMVSS 201 Schedule 4 phase-in requirements outlined in the Code of Federal Regulations (CFR) 49. These requirements (effective September 1, 2009) pertain to the upper interior test criteria specific to final-stage and altered vehicle manufacturers. Webinar attendees will learn about the following topics:  
 
-  Introduction to FMVSS 201U testing and requirements  
-  Final-stage and altered vehicle manufacturer test exemptions  
- Overview of the target locations and critical notes for design countermeasures

Read More...
"X" Marks the Spot
Andy Gould - Troy, MI (andrew.gould@mgaresearch.com
 
For many years MGA has been recognized as an industry leader in FMVSS 200 series validation, notably seat and seat belt anchorage (207/210) testing.  One of the most important aspects in preparing for these particular tests is to obtain an accurate center of gravity (CG) location as well as seat weight, since both of these properties are critical to the NHTSA test procedure. The FMVSS 207 Forward and Rearward Longitudinal Strength Tests both require the test load, (20 times the heaviest seat weight) to be applied to the seat through its complete seat CG.
 
  Dwight Bruce - CG

The CG determination procedure is started by allowing the seat to hang freely from its two rear anchor mounts using a linear rod and custom hooks. A plumb-bob is hung vertically from the same rod, and a line is traced across the seat where the plumb-bob line crosses it. The steps are repeated while the seat is hung from the front mounting holes. An "X" marks the spot where the seat CG is located.
 
Up Close & Personnel
Meet Paul Sterne
 
Paul Sterne
Paul Sterne has been an MGA Associate for six years, and is Michigan's resident expert of the Weight and CG Determination Measurement Station. He has been heavily involved in the recent improvements to the equipment and test procedure. Paul is also a very accomplished test technician, and has years of experience performing FMVSS 207/210 testing that are associated with the weight and CG measurements.
 
Paul and his wife Joann have been married for 8 years, and have sponsored 2 underprivileged children in India; Alberstar age 11, and Sublayang age 4, for the past 2 years through World Vision; which provides funding for food, school, and healthcare. In his spare time, Paul greatly enjoys working on various art projects including woodcarving and oil painting.
Volume 23 No.: 8
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In This Issue
Featured Article: "Robot-crobatics" at MGA
South Carolina Expansion
MGA Presents FMVSS 201U FMH Webinar
"X" Marks the Spot
Up Close and Personnel - Paul Sterne
Touching Base
Touching Base
with Dr. Patrick Miller - Akron, NY
 
Murphy's
Law and Col. Stapp
 
With the introduction of jet propulsion during the late 1940's, performance characteristics of military aircraft dramatically changed. As a result, the military became extremely concerned with establishing human tolerance data for pilots, both from the standpoint of aircraft control and possible ejection from disabled aircraft. A project to determine human tolerance information was instituted at Muroc Field (now known as Edwards Air Force Base) in 1948. The tests used a rocket sled mounted on railroad tracks with hydraulic brakes at one end to stop the sled. With this setup, speeds as high as 600 mph were possible.

The tests were conducted by Colonel John Stapp, a physician with an engineering background. The test results were so profound that the data collected had a significant effect on not only aircraft design, but also automobile crash design. In fact, Col. Stapp devoted much of his latter life to automobile crash injury mitigation.

Edward A. Murphy was a 1940 graduate of the United States Military Academy at West Point. During World War II, he saw service in the Pacific as an accomplished aircraft pilot. After the war, he became interested in aircraft design and went to work as a research and development engineer for the Air Force. It was during this period that he became involved with the rocket sled tests at Muroc and the experiments that would result in the naming of his law.

The early tests at Muroc were conducted with a humanoid crash dummy strapped to a seat on the sled. After these preliminary tests, Col. Stapp decided that he would ride the sled to determine actual human tolerance data. Prior to these tests, it was believed that human tolerance was limited to about 15-20 G's.
(That is, 15-20 times the force of gravity). Over time, Col. Stapp survived forces exceeding 40 G's for time periods exceeding one second. These results greatly changed subsequent aircraft design, for it was now possible to eject pilots, if necessary, at speeds well in excess of 600 mph and expect them to survive. Equally important, motor vehicles are now designed to undergo highway accidents, where occupants will survive exposures perhaps as high as 40 G's. These accomplishments had their foundation with the early work at Muroc Field.

The program was not without several trying incidents. In 1949, the accuracy of the accelerometers was questioned. Captain Murphy, in charge of the instrumentation, decided to use a new type of strain gage accelerometer and a test was conducted.
Natalee Ramsden
MGA Research Corporation
(888) MGA-LAB1