Technical Bulletin

THOR Specification andCertification
Version 1.2

November 2020
TB 026

TitleVersionDocument NumberAuthor
Date
Related Documents
StatusApplication Date

THOR Specification and Certification
1.2
TB 026B Been & J Ellway
24th November 2020
MPDB Testing Protocol
Information
1st January 2021

Copyright ©Euro NCAP 2020 - This work is the intellectual property of Euro NCAP. Permission is granted forthis material to be shared for non-commercial, educational purposes, provided that this copyrightstatement appears on the reproduced materials and notice is given that the copying is by permission ofEuro NCAP. To disseminate otherwise or to republish requires written permission from Euro NCAP.

Preface
In 2020 the European New Car Assessment Programme (Euro NCAP) updated its offset
frontal impact test procedure. These updates are centred on the adoption of the Thor
anthropometric test device and a new barrier face for the mobile progressive deformablebarrier (MPDB).
This Technical Bulletin details the specification of the THOR dummy specification andcertification corridors.
DISCLAIMER: Euro NCAP has taken all reasonable care to ensure that the information
published in this document is accurate and reflects the technical decisions taken by theorganisation. In the unlikely event that this protocol contains a typographical error or any
other inaccuracy, Euro NCAP reserves the right to make corrections and determine theassessment and subsequent result of the affected requirement(s).

EUROPEAN NEW CAR ASSESSMENT PROGRAMME (Euro NCAP)

Table of Contents
1.

THOR Specification ............................................................................................................... 1

2.

THOR Certification ................................................................................................................ 2

3.

Inspections ............................................................................................................................. 6

1.

THOR Specification

1.1

The THOR dummy to be used in the MPDB test shall conform to standard buildlevel B (SBL-B) following the THOR-50M drawing package August 2018 as
published by NHTSAi. However, the following modifications shall be made.

1.2

The dummy shall be equipped with an onboard data acquisition system for bothcertification and Euro NCAP testing.

1.3

Minor deviations of the shoulder assembly from the NHSTA published drawings areacceptable, provided that these are approved according to the most up to date versionof TB029.

1.4
1.4.1

Spine
The THOR dummy shall be equipped with a four-position spine box set to the‘slouched’ posture which is equivalent to +9°.
The spine box offers only four posture adjustments, -9° erect posture, 0° neutralposture, +9° slouched posture and +12° super slouched posture.
Alternative spine box designs may only be used where data has been provided toshow equivalence between the NHSTA spine assembly and modified spine
assembly.

1.4.2
1.4.3

1.5
1.5.1

Lower Legs
The THOR dummy shall be equipped with Hybrid III 50th percentile lower legs,
including Mil Spec shoes, HIII knee slider sensor and roller ball-bearing knees shallbe fitted. The interface between the THOR 50% upper legs and the Hybrid III lowerlegs will be at the HIII ball bearing knee slider/ THOR knee.

Version 1.2
November 2020

12.
2.1

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6

THOR Certification
The THOR dummy shall be certified in accordance with procedures specified in
THOR 50th Percentile Male (THOR-50M) Qualification Procedures Manual,
September 2018ii, limited to the following dummy segments and tests. (Other tests
specified are not applicable and replaced by items 2.5, 2.6 and 3.1).
Head Impact Test
Neck Tests, all 6 six conditions
Upper Thorax Impact at 4.3m/s
Left and Right Lower Thorax Impact
Abdomen Impact
Left and Right Upper Leg Impact

2.2

Test impact conditions (test fixture, impactor mass, velocity, geometry, etc.) asspecified shall apply.

2.3

Thorax and abdomen displacement sensors and their data processing shall comply
with as specified in ISO TS21002iii.

2.4

Certification corridors as specified in Table 1 through Table 9 shall apply. Note:neck pendulum deceleration pulse corridors changed per NHTSA 2018 qualification
manual due to implementation of a more accurate method to determine time zero.
This leads to a minor time shift, hence the small shift in pendulum pulse definitions
with respect to the previous versions of TB026.

2.5

The knee sliders shall be certified to SAE J2876 after every THREE impact tests andas specified in SAE J2856 after every NINE impact tests. See Technical Bulletin
TB006 for more details.

2.6

The HIII lower legs shall be certified in accordance with procedures specified inAnnex 10 of ECE Regulation No. 94.

Table 1 Neck Flexion Certification corridors
Parameter

Units

Pendulum velocity
Pendulum velocity @ 8ms after T0
Pendulum velocity @ 16ms after T0
Pendulum velocity @ 24ms after T0
Peak upper neck My
Upper neck Fz most positive value
prior to 40ms
Peak head angular velocity (relativeto earth)
Peak head rotation (relative topendulum)
Version 1.2
November 2020

UpperLimit
5.05
1.92
3.82
5.41
31.5
961

Widthm/s
m/s
m/s
m/s
NmN

Lower
Limit
4.95
1.57
3.13
4.42
27.3
835

deg/s

-1993

-1732

7%

deg

-65.3

-56.7

7%

1%
10%
10%
10%
7%
7%2

Table 2 Neck Extension certification corridors
Parameter

Units

Upper
Limit
5.05
2.12
4.04
5.54
-20.4-2539
2267

Widthm/s
m/s
m/s
ms/NmN
deg/s

Lower
Limit
4.95
1.74
3.30
4.53
-24.9-3103
1855

Pendulum velocity
Pendulum velocity @ 10ms after T0
Pendulum velocity @ 20ms after T0
Pendulum velocity @ 30ms after T0
Peak upper neck My
Peak upper neck Fz
Peak head angular velocity (relativeto earth)
Peak head rotation (relative topendulum)

deg

57.1

69.8

10%

Upper
Limit
3.45
1.30
2.553.86
51.5

Width

Upper
Limit
5.05
2.09
3.14
4.23
5.22
43.6
1563

Width1%
10%
10%
10%
10%
10%
10%

Table 3 Neck Lateral Left and Right certification corridors
Parameter

Units

Lower
Limit
3.35
1.06
2.09
3.16
44.8

Pendulum velocity
m/s
1.5%
Pendulum velocity @ 4ms after T0m/s
10%Pendulum velocity @ 8ms after T0m/s
10%Pendulum velocity @ 12ms after T0m/s
10%Upper Neck Mx first peak after
Nm7%
40ms*
First peak head angular velocity*
deg/s
1256
14457%(relative to earth)
Peak head rotation relative todeg
38.0
43.8
7%
pendulum**specifications are presented as absolute values to accommodate both left & right impacts
Table 4 Neck Torsion Left and Right certification corridors
Parameter

Units

Lower
Limit
4.95
1.71
2.57
3.46
4.27
37.9
1358

Pendulum velocitym/s
1%
Pendulum velocity @ 10ms after T0m/s
10%Pendulum velocity @ 15ms after T0m/s
10%Pendulum velocity @ 20ms after T0m/s
10%Pendulum velocity @ 25ms after T0m/s
10%Peak upper neck Mz*
Nm7%
Peak upper neck angular velocity*
deg/s7%(relative to earth)
Peak neck fixture rotation* (relativedeg
43.0
49.57%to pendulum)*specifications are presented as absolute values to accommodate both left & right impacts
Version 1.2
November 20203

Table 5 Head Impact certification corridors
Parameter

Units

Lower limit

Pendulum velocity
Peak probe force
Peak head CG resultant acceleration

m/s
Ng

1.95
4890
104.9

Parameter

Units

Lower limit

Pendulum velocity
Peak probe force
Peak upper left resultant deflectionPeak upper right resultant deflection
Ratio of left z- and x-deflection attime of peak resultant deflection
Ratio of right z- and x-deflection attime of peak resultant deflectionm/s
Nmmmm-Upper
Limit
2.05
5976
120.7

Width

Width

4.25
2642
47.5
47.5
0.62

Upper
Limit
4.35
3039
54.7
54.7
0.75

0.62

0.75

4%*

Upper Limit
4.35
3880
-45.6

Width
1.2%
7%
7%

2%
10%
7%

Table 6 Upper Thorax 4.3m/s

1.2%
7%
7%
7%
4%*

* Relative to mean of resultant deflection corridor

Table 7 Left and Right Lower Thorax certification corridors
Parameter
Pendulum velocity
Peak Probe Force
Peak left and right lower X-axis
rib deflection

Unitsm/s
N
mm

Lower limit
4.253372-52.4

Table 8 Lower Abdomen certification corridors
Parameter
Pendulum velocity
Peak probe force
Lower left abdomen X-axis
deflection @ peak force
Lower right abdomen X-axis
deflection @ peak force
Difference between L&R X-axis
deflections @ peak force

Version 1.2
November 2020

Unitsm/s
Nmm

Lower limit
3.252572-83.8

Upper Limit
3.353143
-72.8

Width
1.5%
10%7%mm-83.8-72.8

7%mm-8n.a.

4

Table 9 Left and Right Upper Leg certification corridors
Parameter
Pendulum velocity
Peak Probe Force
Peak Femur Force FzPeak Resultant Acetabulum
Force
Left Acetabulum Fx @ peak
resultant acetabulum force
Right Acetabulum Fx @ peak
resultant acetabulum force

Version 1.2
November 2020

Unitsm/s
NNNLower limit
2.55
4221
-3314
1478

Upper Limit
2.65
5158
-2712
1806

Width
2%
10%10%
10%

N0-n.a.

N-0n.a.

5

3.

Inspections

3.1

PADI
3.1.1 Refer to the NHTSA Procedure for Assembly, Disassembly, and Inspection(PADI)ii August 2018 for detailed instructions on THOR-50M. Section 18 provides
a tester’s checklist as starting point.
3.2
Chest and abdomen displacement sensors
3.2.1 Ensure that chest and abdomen displacement sensors (IR-TRACCs, etc..) are offset
corrected in the data acquisition system according ISO TS21002 and are within
expected range in its zero-position.
3.3
Face foam
3.3.1 The face foam shall be inspected during regular certification of the dummy (afterevery three tests) or when the head lower performance was exceeded.
3.3.2
During the course of testing, normal wear on the foam has been observed by THORusers. This wear may be in the form of small tears or abrasions on the rear surface(Figure 1). Surface wear and small tears on the foam are normal and do not adversely
affect the performance of the head assembly.
3.3.3
The head assembly consists of a specially designed Confor facial foam (p/n 4721401) sandwiched between the skull assembly and the head skin (Figure 2). The foam
can be inspected by removing the skull cap on the rear of the head (remove fourscrews). Then pull the dummy skin forward around the skull. The foam sits inside
the head skin and can be taken out once the skin is removed from the head.
3.3.4
The foam shall be replaced if multiple large cracks are present on the rear face of thefoam, see Figure 3-left.
3.3.5
Assembly of face foam, head skin and skull cap is in reverse order.
3.3.6
No foam certification test is specified at this point, but one may be implemented ata later date.

Figure 1 Small tears in rear surface of the foamVersion 1.2
November 2020

Figure 2 Head Assembly exploded view

6

Figure 3 Face foam seen from the back, new condition (left), replace if multiple large cracks appear(right)

ihttps://www.nhtsa.gov/filebrowser/download/178861 THOR-50M Drawing Package August 2018ii

https://www.regulations.gov/docket?D=NHTSA-2019-0106 THOR-50M Qualification Procedures
Manual September 2018, and Procedure for Assembly, Disassembly, and Inspection (PADI).
ISO TS21002, “Road vehicles – Multidimensional measurement and coordinate system definition”
2021.
iii

Version 1.2
November 20207