Phase I and II Final Report On The Development of A Net Couch Restraint System

GPO
CFST
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REPORT NO DR-5893 1
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(CO €1
WEBER A I R C R A F T
L'IVl5lON O f W 4 i T F h. h1:)DE h COMPANr "4,
BURBANK, CALIFORNIA
ENGINEERING REPORT
DR 5893
PHASE I 6 I1 FINAL REPORT
THE DEVELQPMWT OF A UNI-DIR.ECTIONAL LICI'HTWEIGNT ENERGY

ABSORBING NET COUCH-RESTRAINT S Y S m FOR USE
I N THE A P O U O OK FOLLOW-ON PROJECTS
PREPARED FOR
NATIONAL AERONAUTICS AND SPACE ~ I N I S T R A X I Q N

MANNED SPACECRAFT CENTER
S Y S T m S DIVISION
H o u s t o n , Texas
C o n t r a c t No. WAS 9-3497

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE & COMPANY. I N C .
BURBANK, CALIFORNIA 91 503
FOREWORD
h i s r e p o r t was prepared by Weber A i r c r a f t , Division of Walter Kidde &
Company, Inc., 2820 Ontario S t r e e t , Burbank, C a l i f o r n i a , on National
Aeronautics and Space M m i n i o t r a t i o n Contract No. NAS 9-3497 "Uni-
d i r e c t i o n a l Lightweight Energy Absorbing Net Couch R e s t r a i n t System f o r
use i n t h e Apollo o r Follow-on Projects". The work was administered
under t h e d i r e c t i o n of t h e Crew Systems Division of t h e NASA Manned
Spacecraft Center with Mr. Douglas J. Geier, Head of t h e Acceleration
P r o j e c t s Section a c t i n g as Technical Nonitor.
This document i s prepared i n accordance with t h e Contract Schedule,
Bart VIII - Reports of Work, paragraph 3 - F i n a l Repart, and i a submitted
t o f u l f i l l the contractural obligation specified therein. A l l work on
t h i s developnmt program has been conducted by d i r e c t i o n of t h e Engineer-
i n g Department,, under t h e Weber A i r c r a f t P r o j e c t Number 537. This
document has a Weber A i s c r a f t Report No. DR 5893.
Weber A i r c r a f t wishes t o acknowledge t h e c o n t r i b u t i o n s of Mr. D. Johansen,
P r o j e c t Engineer a t Weber, and M r . M. Olson of t h e United state^ Rubber
Company under subcontract t o Weber, who were p r i m a r i l y r e s p o n s i b l e f o r
t h e development o f t h e Energy Abeorbing Net Couch - Restraint System.
REPORT NO. DR 5893 PAGE i

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY. INC
ABSTRACT
The developuent of t h e Apollo Energy Absorbing Net Couch - Restraint

System was performed by Weber A i r c r a f t between October 1964 through
August 1966. The F i n a l Report DR 5893 summarizes t h e t e c h n i c a l t a s k s
performed d u r i n g t h i s p e r i o d i n t h e d e s i g n , development, t e s t i n g and
f a b r i c a t i o n of a p r o t o t y p e system which would be i n t e r c h a n g e a b l e w i t h
t h e e x i s t i n g hard couch system i n t h e Apollo s p a c e c r a c t . The progran
was d i v i d e d i n t o two phases i d e n t i f i e d as a development phase and a
f a b r i c a t i o n phase. The development phase was p r o p o r t i o n e d t o t a k e
advantage o f t h e s t a t e - o f - t h e - a r t t e c h n i q u e s i n t h e f i b r e and f a b r i c
processing industry. These t e c h n i q u e s were u t i l i z e d t o d e v e l o p a body
s u p p o r t i n s e r t c o n c e p t which would a t t e n u a t e a 50-g impact f o r c e t o 20-g
a s f e l t by an anthropomorphic dummy. Three f a b r i c a t i o n tecl'niques, each
prepared by a d i f f e r e n t s u p p l i e r , were a n a l y z e d by Weber and e v a l u a t i o n
tests performed. A s a r e s u l t t h e t w i s t e d c o r d f i l a m e n t wound c o n s t r u c t i o n
concept, u t i l i z i n g undrawn nylon f i b e r s , was s e l e c t e d f o r t h e p r o t o t y p e
couch system.
Phase I1 - F a b r i c a t i o n and T e s t of t h e Couch System - was provided first,
t o i n c o r p o r a t e m o d i f i c a t i o n s r e s u l t i n g from t h e Phase I tests; second, t o
perform a d d i t i o n a l tests; and t h i r d , t o d e s i g n and f a b r i c a t e a t h r e e man
couch system c a p a b l e o f b e i n g i n s t a l l e d i n t h e Apollo Comand Module.
A s a d i r e c t r e s u l t o f t h i s developmert program, i t may b e coccluded t h a t
t h e u s e o f undrawn nylon f i b e r s t o a t t e n u a t e impact f o r c e s w i t h i n t h e
-- -
REPORTNO. DR 5893 PAGE ii

WEBER AIRCRAFT
DIVISION O F W A L T E R KlDDE & COMPANY INC
ABSTRACT - Continued
l i m i t s of human t o l e r a n c e i a a very p r a c t i c a l method t o a f f o r d crew
p r o t e c t i o n from wergency load c o n d i t i o n s . The n e t couch system weight
i s l e s s than one h a l f t h a t of t h e p r e s e n t hard couch system and can b e
removed, folded, and s t o r e d i n t h e v e h i c l e d u r i n g space f l i g h t . All
o b j e c t i v e s set f o r t h i n t h e i n i t i a l phases of t h e program have been m e t
o r exceeded. It i s believed t h a t a q u a l i f i e d man-rated system employing
t h e concept developed, can h e p e r f e c t e d f o r t h e Apollo Comand Module o r
o t h e r Manned Space Vehicles. It i s estimated t h a t an 18 month program
would be required t o d e l i v e r t h e f i r s t o p e r a t i o n a l production Apollo system.
REPORT NO. DR 5893 PAGE iii

WEBER AIRCRAFT
TABLE OF CGNTENTS
Section Description
1.0
PROGRAM PLAN
PHASE I-TASK A-DEVELOPMENT AND EVALUATION

OF BODY SUPPORT CONCEPTS
Concept Evaluation Procedure

Woven Fabric, Tape Construction Body
Support Concept
Braided Cord, Knitted Construction Concept
Twisted Cord, Filament Wound C o n s t r u c t i o n
Concept
Summary of Concept Evaluation T e s t Program
PHASE I -
TASK B-DESIGN AND DEVELOPMENT
OF COUCH SYSTEM
Performance Requirements
Framework Development
Body Support and R e s t r a i n t Development
Body Support Design
Procedure f o r C a l c u l a t i n g Filament Wound
Energy Absorbing Cord D i s t r i b u t i o n
R e s t r a i n t Harness Design
Headrest and Leg S e p a r a t o r Design
Prototype Couch Frame Development T e s t i n g
NASA-MSC Supplemental T e s t s
PHASE II - FABRICATION AND TEST

Three Couch System
Phase I1 Couch M o d i f i c a t i o n and T e s t s
A d d i t i c n a l P r o t o t y p e Couch T e s t i n g
Body Support S e c t i o n T e s t s
Body Support Design Summary
CONCLUSIONS AND RECOMMENDATIONS
Conclusions
Recommendations
REPORT NO. DR 5893 FAGE iv

WERER AIRCRAFT
DIVISION OF W A L T E R KlDDE 61 C O M P A I V Y . I Y L
LIST OF ILLUSTRATIONS
Figure -
Title Page
1 Sketch o f Apollo Net Couch System 2
2 Apollc N e t t i n g Type Couch Development P l a n 4
3 Woven F a b r i c Tape C o n s t r u c t i o n Concept 13
4 S t a t i c Load -
E l o n g a t i o n of a Load B e a ~ L ? g
Assembly, Woven Tape Concept 21
5 Dynamic Load -
E l o n g a t i o n o f a Load B e a r i n g
Assembly, Woven Tape Concept 22
6 Load E l o n g a t i o n Curves f o r T r e a t e d Nylon and

Dacron Yarns T e s t e d a t 30 F e e t P e r Second 32
7 C o n s t r u c t i o n D e t a i l K n i t t e d Cord Concept 38
8 Braided Cord K n i t t e d C o n s t r u c t i o n Cord Concept 35
9 S t r e s s - S t r a i n Curves o f V a r i o u s Nylon 6 F i l a m e n t
Constructions 41
10 S t r e s s - S t r a i n V a r i a t i o n s on 750 Denier Undrawn

Nylon 6 Yarn 43
11 E f f e c t o f M o i s t u r e on S t r e s s - S t r a i n o f 750
Denier Undrawn Nylon 6 Yarn 45
12 E f f e c t o f Temperature a n S t r e s s S t r a i n o f
750 Denier Undrawn Nylon 6 Yarn 46
13 S t r e s s - S t r a i n C h a r a c t e r i s t i c s o f Untwisted
Undrawn Yarn v s 3-Ply Twisted Cord 47
14 Load A t t e n t l a t i o n Curve f o r T e s t S p e c i f i c a t i o n ,
P r o p o s a l "A", F i l a m e n t Wound Concept 51
15 Load A t t e n u a t i o n Curve f o r T e s t S p e c i f i c a t i o n ,
P r o p o s a l "B" F i l a m e n t Wound Concept 52
16 Couch D e f l e c t i o n Curves on H a l f - S c a l e P l a t f o r m
Model F i l a m e n t Wound Concept 53
17 Load T r a c e un H a l f - S c a l e Drop T e s t F i l a m e n t
Wound Concept 57
REPORT NO. DR 5893 PAGE v

WEBER AIRCRAFT
DIVISION OF W A L T E R KtDDE & COMPANY INC
..-
LIST OF ILLUSTRATIONS - Cont.
-
Figure -
Title Page
18 Cord Distribution Filament Wound Concept 60
19 Stress Strain of 840 Denier Nylon 300

Stabilizing Cord
20 Static Test Set Up
21 Dynamic Attenuating Characterist!~~of the

Three Body Support Concepts
22 Dynamic Test Set Up
23 Dynamic Test on Apollo Couch Filament Wound

System
24 Couch Assembly
25 Couch Frame Structure in Stowed Configuration
26 Attachment of Eody Support to Couch Frame
27 Body Support and Restraint Assembly
28 Physical Characteristics of 3 Ply-840 Denier

Nylon At ter~uatingCord
29 Attenuating Links of the Restraint System
30 Completed Body Support Assembly
31 Supplemental Drop Test Accelerometer Data

32.8 FPS Velocity Change
32 Supplemental Drop Test Accelerometer Data

32.4 FPS Velocity Change
33 Supplanental Drop Test Data Body Support

-
Assembly 33.0 FPS Velocity Change
34 Supplemental Drop Test Data Body Support

-
Assembly 31.0 FPS Velocity Change
35 Supplemental Drop Test Data Body Support

-
Assembly 30,O FPS Velocity Change
REPORT NO. DR 5893 PAGE vi

WEBER AIRCRAFT
DIVISION O F W A L T E R KlDDE & COMPANY. INC
LIST OF ILLUSTRATIONS - Cont.

Figure Title Page
36 Supplemental Drop T e s t Data Body Support

Data -
30.8 FPS V e l o c i t y Change 123

Assembly -
32.0 FPS V e l o c i t y C h a ~ g e 124

Assembly -
33.0 FPS V e l o c i t y Change 125
39 Suspension S t r x t u r e f o r Three Couch System 13C
40 Apollo Net Couch System 131
41 Prototype Tests - -
Drop 1 MSC B o i l e r p l a t e
Couch w i t h Secondary Lacing 141
42 Prototype Teet -
Drop 2 -
MSC d o i l e r p l a t e
Couch Secondaiy L a c i n g Removed 142
43 Prototype Test -
Drop 3 -
Weber Couch -
Seconaary Lacing R m w e d 143
44 Drop T e s t No. 3 - Dumny i n Atteliuated P o s i t i o n 144
45 Body Support S e c t i o n Drop T e s t 5 (High T e n a c i t y

Rayon Lacing) 153
46 Body Support S e c t i o n Drop T e s t 8 ( F i n a l Design

C o n f i g u r a t i o n Dacron 52 Lacing) 154
47 Body Support S e c t i o n Drop T e s t 11 (PrSmary

Cords Only) 155
48 Body Support S e c t i o n Drop T e s t 12 (Dacron 52

L a c i n g wieh Rubber Lined Grommets) 156
49 O p e r a t i o n a l Apollo Crew Couch Program P l a n 175
REPORT NO. DR 5893 PAGE vii

WEBER AIRCPAFT
DIVISION O F W A L T E R KIDDE €31 C D M P A N Y . IIdC
BURbANK, CALIFORNIA 91 503
LZST OF TABLES
-
Table Title
1 Sumnary of S u p p l i e r E v a l u a t i o n Rarame ter s
2 P o i n t R a t i n g of Each System Concept
3 T e n s i l e T e s t Data o f N-13 Nylon Yarn (965

d e n i e r , 34 f i l a m e n t s )
4 T e n s i l e T e s t Deta o f Dacron Yarns
5 T e n a i l e T e s t Data o f Formic Acid T r e a t e d

Nylon Yarns
6 T e n s i l e T e s t Data of Formic Acid T r e a t e d

Nylon Tapes
7 Proposed T e s t S p e c i f i c a t i o n s
8 Sumniary Drop T e s t R e s u l r q - F i l m e . l t Wmnd

Concept
9 Average d t a t i : Load Def l e c + i o n s , Summary
10 Sumnary Dynamic Data
11 D e v i a t i o n From Uniform Dynamic Response
12 P r e d i c a t e d va. A c t u a l Duimy Response, F i l a m e n t

Wound Concept
13 Primary Support System S u b d i v i s i o q C o n f i g u r a t i o n

and I n p u t C h a r a c t e r i z a t i o n S m a - y
14 Sample Cr~mputer P r i n t - O u t C a l c d a t i o n
15 S t a t i c T e s t Data - P r o t o t y p e Cc c h Assembly
16 Dynamic T e s t D a t s - Protocype Couch Assembly
17 Supplemental NASA-MSC Dro; T e s t g-Force Data
18 Supplemental NASA..MSC Drop T e s t - Deflection

Data
REPORl NO. DR 5893

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & C O M P A N Y . I N C
LIST OF TABLES - CO. t.

Table -
Title
19 Attenilating Cord Draw Force Tests
2G Prototype Couch Drop Tests 137
21 Lacing Cord Characteristics 149
22 Body Support Section Drop Tests 15 1
23 Secondary Lacing S t s t i c Load Tests 12"

Section
24 Crew Couch Load Requirements - Apollo

Translunar Mission
25 Environmental Conditions - Apollo Translunar

Mission 170
REPORT NO. DR 5893 PAGE ix

WEBER AIRCRAFT
DIVISION OF WALTER KIDDE & COMPANY. INC
1.0 INTRODUCTION
Weber A i r c r a f t was awarded t h e N a t i o n a l A e r o n a u t i c s and Space
A d m i n i s t r a t i o n C o n t r a c t No. NAS 9-3497 t o develop an u n i d i r e c t i o n a l
n e t t i n g t y p e crew couch system which would be i n t e r c h a n g e a b l e
v i t h t h e e x i s t i n g hard couch system i n t h e Apollo s p a c e c r a f t .
The system develaped by Weber, shown i n F i g u r e 1, u t i l i z e s un-
drawn nylon f i b e r s i n t e g r a t e d i c t o a body s u p p o r t assembly which
i s a t t a c h e d t o a l i g h t w e i g h t monocoque alminurn s h e e t m e t a l
couch frame. During predetermined impact c o n d i t i o n s t h e nylon
f i b e r s a r e s u b j e c t e d t o f o r c e s which c a u s e m o l e c u l a r r e a l i g n m e n t
of t h e randomly o r i e n t e d m o l e c u l e s i n t h e undrawn f i b e r s , producing
a p l a s t i c -1ysteretic displacement a t a constant f o r c e l e v e l ,
r e s u l t i n g i n t h e d e s i r e d a t t e x a t i o n of t h e couch occupant.
The i n d i v i d u a l couches a r e mounted on a r i g i d i n t e r m e d i a t e
s t r u c t u r e which u s e s t h e same a t t a c h m e n t l o c a t i o n s and f i t t i n g s
a s t h e e x i s t i n g hard couch i n t h e Apollo Conanand Module.
T h i s f i n a l r e p o r t summarizes t h e t e c h n i c a l t a s k r e s u l t i n g :om
Phase I and I1 of t h e d e s i g n , development, t e s t i n f and f a b r i c a t i o n
of a p r o t o t y p e couch system a s r k q u i r e d i n P a s t V I I I , Item 3
of the Contract.
REPORT NO. DR 5893 PAGE 1

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE & COMPANY. INC
BURBANK, CAilFORNlA 91 503

WEBER ALRCRAFT
DI.dISION OF W A L T E " K I J D L : & C G M P A N Y . I N C
BURDAPlK, CALiFORNlA 91 503
2 .O PP.OGRN: PLAN-
The program was d i v i d e d i n t o two m a j o r p h a s e s , a d e s i g n -
development p h a s e and a f a b r i c a t i o n p h a s e i d e n t i f i e d as Ph:se I
and Phase 11, r e s p e c t i v e l y , The design-development p h a s e was
f u r t h e r d e f i n e d as h a v i n g two d i s r i n c t s u b t a s k s ; Task A - Develop-

m m o f a Body S u p p o r t Concept, and Task B - Development o f a
Couci~ System.
Tile p h a s e s and t a s k s were f u r t h e r s u b d i v i d e d , as shown j n F i g u r e 2,
i n r . 0 t h e m a j o r e l e m e n t s o f d e s i g n , f a b r i c a t i o n and t e s t i n g
r e q u i r e d t o c o m p l e t e t h e prosram. The e f f o r t r e l a t e d t o b o t h
P h a s e I and Phase I1 o f t h e program i s d i s c u s s e d i n t h e f o l l o w i n g
sections.

WEBER AIRCRAFT COMPANY
.4 Divisicn o f Wolter K ~ d d e8 Cornparly, Inc
Burbank, California
-.--
WEBER AIRCRAFT
DIVISION O F W A L T E R KlDDE & COMPANY. INC
3 .O P U S E I -TASK A - DEVELOPMENT AND EVALUATION OF BODY SUPPORT CONCEPTS

The f i r s t t a s k was t o develop, f a b r i c a t e and test s e v e r a l body
s u p p o r t c o n c e p t s and s e l e c t one which most s a t i s f i e d t h e r e q u i r e -
ments of t h e program. T o t a k e advantage o f t h e s t a t e - o f - t h e - a r t
t e c h n i q u e s i n t h e f i b e r and f a b r i c p r o c e s s i n g i n d u s t r y , i t was
determined t h a t t h r e e t e x t i l e development companies would be
s e l e c t e d and awarded c o n t r a c t s t o d e v e l o p p r o t o t y p e a s s e m b l i e s
f o r t e s t i n g and e v a l u a t i o n by Weber.
To accomplish t h i s , a s t a t e m e n t o f work (Reference 1) was p r e p a r e d
a ~ ad n e v a l u a t i o n procedure ( R e f e r e n c e 2) was e s t a b l i s h e d . The
work s t a t e m e n t c o n s i s t e d , e s s e n t i a l l y , o f i s o l a t i n g t h e body s u p p o r t
r e q u i r e m e n t s from t h e couch system performance p a r a m e t e r s s p e c i f i e d
i n t h e c o n t r a c t and were provided t o e a c h s u p p l i e r . T h i s work
statement contained t h e following b a s i c requirements:
The p r o t o t y 2 e assembly s h a l l be o f f a b r i c c o n s t r u c t i o n and i s
r e q u i r e d t o reduce, by p l a s t i c d e f o r m a t i o n , ,? 50-g impact (30 f p s ,
e y e b a l l s - i n ) t o a 20-g l e v e l a s f e l t by a n anthropomorphic dummy.
An a l l o w a b l e occupant d i s p l a c e m e n t o f 1 2 i n c h e s from a no l o a d
(zero-g) p o s i t i o n i s p e r m i s s i b l e t o a t t e n u a t e t h e maximum impact
forces.
The p r o t o t y p e assembly a l s o s h a l l e l a s t i c a l l y s u p p o r t an occupant

a t a s u s t a i n e d 9-g f o r c v l e v e l . For s t a t i c 9-g l o a d s , an occupant
displacement of t h r e e inches i s permitted. From no l o a d t o 1-g, a
d i s p l a c e m e n t of one and one-half i n c h e s i s allowed.

-
REPORT NO. ~2 5893 PAGE 5
WEBER AIRCRAFT
3.0 BODY SUPPORT CONCEPT DEVELOPMENT ( c o n t i n u e d )
The body s u p p o r t s h a l l a c c o m o d a t e o c c u p a n t s i n t h e 1 5 t h t o 9 0 t h
p e r c e n t i l e s i z e and w e i g h t range. Upon dynamic d i s p l a c e m e n t o f
t h e body s u p p o r t , t h e d e f l e c t i o n s h a l l b e u n i f o r m w i t h o u t a d j u s t -
ments t o t h e assembly. A d d i t i o n a l l y , t h e f i b e r s used i n t h e s y s t e m
s h a l l b e r e a d i l y a v a i l a h l e ; a t t a c h m e n t t o t h e couch framework s h a l l
b e o f a c o n c e p t which l e n d s i t s e l f t o a method which c o u l d p e r m i t
a c r e w member t o r e p l a c e t h e body s u p p o r t d u r i n g s p a c e f l i g h t .
Weber p r o v i d e d e a c h s u p p l i e r w i t h a b o i l e r p l a t e framework on
which t h e s u p p l i e r a t t a c h e d t h e body s u p p o r t assembly. A second
body s u p 2 o r t a s s e m b l y was p r o v i d e d b y t h e s u p p l i e r f o r t e s t and
e v a l u a t i o n a t Weber .
*
J.A
-
-
Concept Evaluation Procedure
Each s u p p l i e r was p r o v i d e d w i t h a n e v a l u a t i o n p r o c e d u r e
t o a i d i n d e t e r m i n i n g which p a r a m e t e r s c o n t a i n e d t h e most
m e r i t d u r i n g t h e t e s t s t o be performed a t Weber.
The e v a l u a t i o n p r o c e d u r e o u t l i n e d f o u r major a r e a s t o be
considered. Each a r e a was b r o k e n down f u r t h e r i n t o
s p e c i f i c performance parameters. Each p a r a m e t e r was
a s s i g n e d a number from one t o t h r e e t o e s t a b l i s h i t s
weighted v a l u e i n r e l a t i o n t o t h e o t h e r parameters.

WEBER AIP.CRAFT
DIVISION O F WALTER KlDDE & COMPANY. INC.
3.1 Concept E v a l u a t i o n Procedure ( c o n t i n u e d )
The performance o f t h e system was e v a l u a t e d and each
parameter was graded. Each parameter g r a d e , based on t h e
a c t u a l performance of t h e s u p p l i e r ' s e n t r y , and r a n g i n g i n
v a l u e from two t o t e n , t h e n was m u l t i p l i e d by t h e weighted
v a l u e of t h e p a r t i c u l a r p a r a m e t e r b e i n g graded. The
weighted-gradss f o r t h e i n d i v i d u a l p a r a m e t e r s t h e n wcre
added, t h u s o b t a i n i n g a s c o r e f o r t h e t o t a l system. The
s c o r e was t h e b a s i s f o r d e t e r m i n i n g which concept niost
a d e q u a t e l y s a t i s f i e d t h e r e q u i r e m e n t s o f t h e program.
The f o u r b a s i c a r e a s e v a l u a t e d were: General performance,
s t a t i c performance, dynamic performance, t e c n n i c a l p e r -
formance and e x p e r i e n c e of t h e s u p p l i e r . Under g e n e r a l
performance, e i g h t p a r a m e t e r s were e v a l u a t e d and i n c l u d e d
comfort, system weight, m a t e r i a l a v a i l a b i l i t y , s t r u c t u r a l
i n t e g r i t y , and t e c h n i c a l s u p p o r t and a n a l y s i s o f t h e system
by t h e s u p p l i e r . S t a t i c performance i n c l u d e d body s u p p o r t
d e f l e c t i o n a t 1-g and 9-g l o a d s , i t s e l a s t i c i t y , and con-
formance t o t h e occupant shape. I n a l l , s i x parameters
were reviewed.
Run-ravel r e s i s t a n c e , dynamic d i s p l a c e m e n t and a t t e n u a t i n g

0
f o r c e l e v e l s , and t h e amount ~ f p l a s t i c e l o n g a t i o n o f t h e
m a t e r i a l were major items o f t h e s i x p a r a m e t e r s c o n s i d e r e d
d u r i n g t h e dynamic tests.

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & COMPANY. INC
3.1 -
Concept E v a l u a t i o n Procedure (continued )
Reporting methods, equipment and f a c i l b t i e s , s u p p l i e r
background and comprehension of the problem were e v a l u a t e d
in the fourth area.
A summary of t h e e v a l u a t i o n p a r a m e t e r s and t h e weighted
v a l u e f o r e x h a r e a i s shown i n Table 1,
The body s u p p o r t c o n c e p t s t e s t e d and t h e a s s o c i a t e d
e v a l u a t i o n a r e p r e s e n t e d i n d e t a i l i n Reference 3.
Therc were twenty-nine (29) i n d i v i d u a l p a r a m e t e r s t o be
consid.ered, e a c h weighted w i t h v a l u e s r a n g i n g from one ( 1 )
t o t h r e e (3) f o r a t o t a l v a l u e of s i x t y - n i n e (69). When
making t h e e v a l u a t i o n t h e e v a l u a t o r r a t e d each concept as
t e n (10) p o i n t s e x c e l l e n t ; s i x ( 6 ) p o i n t s a c c e p t a b l e , two
(2) points unsatisfactory. A p e r f e c t system would g e t s i x
hundred and n i n e t y (690) p o i n t s from e a c h of t h r e e e v a l u a t i o n
teams f o r a grand t o t a l of two t!~ousand and s e v e n t y (2,070)
points. The t o t a l s c o r e f o r each concept i s broken down
i n t o t h e f o u r (4) g e n e r a l parameter c l . a s s i f i c a t i o n s and is
shown i n Table 2.
The c l o s e grouping of t h e t h r e e system s c o r e s i n d i c a t e s
t h a t e a c h concept was g i v e n c o n s i d e r a b l e thought by e a c h
manufacturer. The time a l l o c a t e d f o r t h i s p o r t i o n of t h e
REPORT NO. nR PAGE 8

WEBER AIRCRAFT
SURBANK, CALIFORNIA 91 503
3.1 Concept E v a l u a t i o n P r o c e d u r e - Cont.

TABLE 1
SUMMARY OF S U P P L I E R EVALUATION PARAMETERS
GENERAL PERFORMANCE IJBIGIITED VALUE
A r t i c u l a t i o n , conformance t o body
s h a p e and p r e s s u r e points............, 2
Distribution of material, s t r e s s
levels................................ 4
Material a v a i l a b i l i t y , system weight

and o v e r a l l c o m f o r t level............. 4
Analysis o f s u p p l i e r developed t e s t
d a t a by s u p p l i e r . . .................... 3
TOTAL
S T A T I C LOAD PERFORMANCE
A b i l i t y t o uniformly support various

body masses and o c c u p a n t size.........
D e f l e c t i o n a t 1-g and 9-g l o a d s ,

l o a d d i s t r i b u t i o n and e l a s t i c i t y , . . . . .
TOTAL
DYNAMIC PERFORMANCE
A t t e n u a t i o n l e v e l , body d i s p l a c e m e n t
r a t e s , s t r u c t u r a l i n t e g r i t y , energy
a b s o r b i n g capacity....... ............
TOTAL
TECHNICAL EXPERIENCE AVD F A C I L I T I E S
G e n e r a l background and c a p a b i l i t i e s
TOTAL

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE 81 COMPANY. INC
BURBANK: CALIFORNIA 91 503
3.1 Concept Evaluation Procedure (continued)
program precluded extensive research i n t o a l l of the
required parmeters and necessitated a certain amount
o f trade-off a s far a s ths individual parmeters are
concerned. This trade-off condition i s a l s o indicated by
the scores being grouped i n the mid-range of the maxinmm
possible points.

WEBER AIRCRAFT
Concept Evaluation Procedure Con t .
POINT RATING OF EACH SYSTPi COKCEPT
SYSTEM PERFCRMANCE PARAMETm SCORE ZiSTEM SCORE

CONCEPT GENERAL STATIC DYNAMIC TECH -
--
Wwen Tape 206 206 7 00 106 1218
Construction
Knitted 194 258 5 12 114 1078

Cord Conet.
Filament 254 234 752 174 1414
Wound Const.
Maximum p o s s i b l e s c o r e , any system - 2070 p o i n t 8

The n e x t phase of t h e body support development w i l l i n c l u d e
remeding t h e a r e a s of weak performance and expanding t h e concept
i n t o an o p e r a t i o n a l system i n c o r p o r a t i n g a r e s t r a i n t system and
an easy attachment method o n t o a p r o t o t y p e couch s t r u c t u r e .
REPORT NO. DR 5893 - PAGE 11

WEBER AIRCRAFT
"VISION OF WALTER KlDDE & COMPANY. !NC
3.2 Woven F a b r i c , Tape Construction Body Support Concept
The woven f a b r i c , t a p e c o n s t r u c t i o n concept was f a b r i c a t e d
by Prodesco, Incorporated, P e r k a s i e , Pennsylvania under
c o n t r a c t t o Weber A i r c r a f t . See F i g u r e 3.
Ths d e s i g n concept i s based on a composite t e x t i l e
structure. .P breakout component i n an e l a s t i c member

permits t r a n s f e r of t h e load t o a h y s t e r e t i c member a t t h e
9-9 load l e v e l , and makes a v a i l a b l e t h e excess l e n g t h i n a
b i g h t (loop) i n t h e e l a s t i c member f o r subsequent energy
absorption. A t the 6m e l o n g a t i o n l e v e l of t h e h y s t e r e t i c
member, t h e b i g h t w i l l have been p u l l e d up t a u t , and t h e
e l a s t i c member w i l l again provide s u p p o r t i n o r d e r t o limit
t h e t o t a l d e f l e c t i o n of t h e n e t platform.
T!le platform c o n s t r u c t i o n r o n s i s t s of a s x i e s of t r a n s v e r s e
t e x t i l e webbing assemblies suspended frcnn t h e s i d e r a i l s of
t h e couc!i frame. There a r e no load b e a r i n g t e x t i l e
assemblies extending i n t h e l o n g i t u d i n a l (head- t o - toe)
direction. These toad b e a r i n g assemblies a r e approximately
0.75 i n c h e s i n width and a r e spaced along t h e l e n g t h of t h e
body support platform according t o t h e a n t h r o p m o r p h i c
weight d i s t r i b u t i o n given i n t h e NASA-MSC statement of work.
Each load b e a r i n g assembly c o n s i s t s of a nylon t a p e w i t h a
b i g h t sewn near one end.
REPORT NO. -DR 5893 PAGE l2

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & C O M P A N Y . INC
3.2 Woven Fabric, Tape Consrruction Body Support Concept - Cont.

The b i g h t 13 closed by a s h o r t piece of c o t t o n tape a c t i n g
a s t h e break-out component i n t h e e l a s t i c s y s t m . Cotton
i s s e l e c t e d because of i t s low e x t e n s i b i l i t y . Holes a r e
punched i n t h e middle of each p i e c e of c o t t o n t a p e t o
i n s u r e t h a t f a i l u r e w i l l occur i n t h e t a p e r a t h e r than a t
t h e sewn seam.
The h y s t e r e t i c m a t e r i a l , i n t h e form of another tape, i s
sewn l i g h t l y t o t h e t a p e mentioned above. The s t i t c h e s
a r e located a t two ends only; t h e r e i s no s t i t c h i n g a c r o s s
t h e t r a n s v e r s e f r e e span.
The v a r i o u s load bearing assemblies are sewn t o a p e r i p h e r a l
frame of heavy nylon webbing. The heavy nylon web i s
a t t a c h e d t o t h e couch frame by grommets and snaps. The
b i g h t i n each loaa bearing assembly i s l o c a t e d a l t e r n a t e l y
along t h e webbing frame t o provide symmetrical displacement
of t h e platform.
The d i s t r i b u t i o n of t h e load b e a r i n g assemblies i s i n
accordance with load c a l c u l a t i o n s . Test data indicates that
79 tape assemblies a r e required.
Legs = 279.~79 = 21 members

Torso = 54.3% x 79 = 5 1 members
Head = 8.7% x 79 = 7 members
REPORT NC. DR 589.3 PAGE 14

WEBER AIRCRAFT
DIVISION OF WALTER KIDDE & COMPANY INC
3.2 Woven F a b r i c , Tape C o n s t r u c t i o n Body Support Concept - Cont.

These a r e minimum q u a n t i t i e s and assume 1009. energy
absorption. Because o f t h e t a p e r e d p l a t f o r m , t h e head
a r e a r e q u i r e s s h o r t e r load bearing assemblies lengths.
S i n c e t h e r e i s l e s s energy-absorbing p o t e n t i a l i n t h i s
z r e a , t h e number o f a s s e m b l i e s was a r b i t r a r i l y i n c r e a s e d t o 9.
For t h i s phase of t h e e f f o r t , t h e r e i s no l o a d on t h e l o a d
bearing assem5lies i n t h e thigh a r e a ; t h e assemblies a r e
p l a c e d t h e r e a t a n a r b i t r a r y o n e . i n c h spacing, t o m a i n t a i n
t h e i n t e g r a l appearance of t h e n e t .
T h i s t h e n r e s u l t s i n a n e t p l a t f o r m with a t o t a l of 102
t r a n s v e r s e l o a d b e a r i n g a s s e m b l i e s ; 81 o f them a r e a c t i v e ,
and l o c a t e d i n t h e heed, t o r s o , and lower l e g a r e a s , and 21
i n a c t i v e mmbers i n the thigh areas. The t o t a l of 8 1
a s s e m b l i e s s h a r i n g t h e l o a d i s determined through t h e i r t o t a l
energy-absorbing p o t e n t i a l . T h i s t o t a l numb2r, when checked
on a f o r c e b a l a n c e b a s i s , show.; t h a t 81 a s s e m b l i e s , each
wirh a break-out s t r e n g t h o f 25 l b s . , w i l l provide a t o t a l
break-out l o a d of approximately 2000 l b s . T h i s w i l l be an
a d e q u a t e d e s i g n l e v e l , s i n c e t h e 2000 l b s . combined s t r e n g t h
i s g r e a t e r t h a n t h e 1750-lb t o t a l l o a d p r o j e c t e d f o r a 9-g
s t a t i c l o a d i n g , and l e s s t h a n t h e 2250-1b t o t a l l o a d i n g a t
t h e u l t i m a t e 20-g l o a d level. Therefore, i f loads a r e

WEBER AIRCRAFT
DIVISION O F W A L T E R K I D D E & C O M P A N Y . I N C
3.2 Woven F a b r i c , Tape C o n s t r u c t i o n Body Support Concept - Cont.
a d e q u a t e l y d i s t r i b u t e d , t h e break-out system w i l l f u n c t i o n
a t a load 1-eve1 above t h e 9-g s t a t i c s t r e n g t h requirement,
and below t h e 20-g f i l t e r l e v e l .
3.2.1 Deslgn C a l c u l a t i o n s
A s a f i r s t o r d e r approximation, t h e v a r i o u s l y deformed c r o s s
s e c t i o n s of t h e n e t platform, under t h e weight of t h e
occupant whether 1-g o r 20-g's, a r e assumed to be segments
of c i r c u l a r a r c s .
Assume a 225 pound occupant, under a 9-g d e c e l e r a t i o n i n
t h e " e y e b a l l s i n " d i r e c t i o n , c a u s e s t h e n e t platform t o
d e f l e c t 3 inches a t its center. For a chord l e n g t h
( d i s t a n c e between t h e s u p p o r t i n g r a i l s ) o f 20 i n c h e s , t h e
a r c l e n g t h corresponding t o t h i s assumed d e f l e c t i o n i s 21.2
inches. The t o t a l t e n s i l e load i n t h e p l a t f o r m i s 1750
pounds .
Assuming t h a t t h e same occupant d i s p l a c e s t h e p l a t f o r m 1 2
i n c h e s under 20-g's, t h e c a l c u l a t e d platform a r c l e n g t h i s
now 35.4 i n c h e s and t h e t o t a l t e n s i l e load 2250 pounds.
T e n s i l e l o a d s a r e c a l c u l a t e d by t h e e q u a t i o n :

WEBER AIRCRAFT
DIVISION OF WALTER KIDDE & COMPAYY. INC
3.2.1 Design C a l c u l a t i o n s
Where :
W = 225 l b s .
0 = t h e included angle between t h e body support

and s i d e r a i l s t r u c t u r e of t h e couch frame
g = acceleration factor
After extensive t e s t i n g o f m a t e r i a l s , Prodesco s t y l e PWC
5-1 twill weave nylon warp webbing, t r e a t e d with formic
acid (HCOOII) was s e l e c t e d f o r use a s t h e h y s t e r e t i c
material.
This t a p e has a s t a t i c breaking s t r e n g t h of 37.0 l b s ,
an elongation t o break of approximately 113% and an
estimated y i e l d s t r e n g t h of 3.3 lbs. with a y i e l d p o i n t
elongation of approximately 12%. A t an elongaSion of 75%,
r e p r e s e n t i n g t h e maximum 12-inch v e r t i c a l d e f l e c t i o n of t h e
couch, t h i s m a t e r i a l has a p r o j e c t e d load b e a r i n g c a p a c i t y
of approximately 28.8 l b s .
Since t h e t o t a l load on t h e couch a t 9-g's has been
estimated a t 1750 l b s . with a maximum t o t a l load of 2250 l b s ,
then t h e load a t break-out ehould be 1750/2250 = 80% of t h e
maximum t o t a l load, and t h e break-out load of each s t r i p

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE & C O M P A N Y . INC.
BURBANK, CALIFORNIA 91503
-
3.2.1 Design Calculations - Cont.

should be 80% x 28.8 = approximately 23 l b s .
h e load j u s t p r i o r t o break-out, should be shared by t h e
h y s t e r e t i c m a t e r i a l , loaded w i t h i n i t s e l a s t i c l i m i t ( l e s s
than 5% elongation) and by t h e break-out s t r i p i t s e l f .
A t 5 2 elongation t h e h y s t e r e t i c members can s u s t a i n loads
of approximately 2 l b s .
The break-out m a t e r i a l s e l e c t e d was a one-half inch wide
c o t t o n tape, with a h o l e punched t o provide a notch e f f e c t
for a controlled localized failure. Tests indicated that
a 3/16" diameter h o l e would a f f o r d a 23-lb breaking
s t r e n g t h , s o t h a t t h e t o t a l break-out load would be apprcx-
imately 23 p l u s 2, o r 25 l b s per s t r i p .
Back-up m a t e r i a l f o r t h e couch must provide support of t h e
a s t r o n a u t during s t a t i c loading, and again a f t e r break-out,
t o l i m i t t h e extreme of h i s d e c e l e r a t i o n displacement.
For t h e assumed loading condition8 and geometry of t h e
couch, the dioplacement l i m i t a t 9-g's corresponds with a
m a t e r i a l elongation of 5% a t r h e equivalent load l e v e l .
Nylon tape, MIL-Spec.T-50384, Type 11, 314 inch wide, was
s e l e c t e d a s having p r o p e r t i e s g e n e r a l l y s u i t a b l e f o r t h i s
eervice.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE 81 COMPANY. INC.
Design C a l c u l a t i o n s - Cont.
A heavier webbing was required f o r t h e p e r i p h e r a l framing
member, and f o r t h i s s e r v i c e , a webbing 1-314 inches wide
was s e l e c ted, g e n e r a l l y s i m i l a r i n c o n s t r u c t i o n ,o MIL-W-
4088B Type V I I I , except m e n from Nomex (HT-1) y a m
i n s t e a d of nylon yarn t o make i t e a s i e r f o r sewing.
Construction of t h i s webbing required a warp of 198 ends
of 8 ply, 200 d e n i e r yarn, and a f i l l i n g of t h e same yarn

of 21 p i c k s per inch. Nominal breaking s t r e n g t h of t h i s
m a t e r i a l i s 3700 l b s .
I n t h e required bent-knee p o s i t i o n , t h e t h i g h s a r e n o t
d i r e c t l y supported i n t h e v e r t i c a l d i r e c t i o n , hence t h e
~ 2 i g h tof t h e t h i g h s i s a r b i t r a r i l y divided and borne
e q u a l l y by t h e t o r s o s e c t i o n and t h e l e g s e c t i o n , t o support
t h i s a d d i t i o n a l mass.
The mass d i s t r i b u t i o n and r e q u i r e d d e n s i t y of support
n t r a p spacing can then be tabulated a s follows:

w
WEBER AIRCRAFT
3.2.1 Design C a l c u l a t i o n s - Cont.
Leg Torso
- - Area
Area- Area
Weight of Man and P r e s s u r e S u i t

(lbs) 51.3 163.3
X of T o t a l 22 70
Lbslinch of Couch Length 2.45 6.8
Length of Man (inches) * 17.6 24
Lbs./inch of Man Length 2.87 6.8
Total Load on Couch, i f body load

extended t o f u l l l e n g t h of couch(1bs) 75 163.3
7. of T o t a l 28.7 62.7
* Note: The thigh i s n o t involved in t h e s e calculat=.ons.
3.2.2 T e n s i l e Testing of Composite Load Bearing Members
Figures 4 and 5 show t h e performance of an energy-absorbing
s t r i p assembly under both s t a t i c and dynamic load conditions.
The s t a t i c t e s t (Figure 4) was conducted on an I n s t r o n
tester. The load was increased t o a p p r o x b a t e l y 60% of t h e
u l t i m a t e s t r e n g t h , and then r e l e a s e d t o show t h e h y s t e r e t i c
energy absorption. A t t h e maximum load level. reached,
t h e back-up s t r i p s had n o t y e t begun t o function.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE 81 COMPANY. INC
-- - C a n t .
Tenmile Testing of Camposite Load Bearing Hemberu
ELONGATION ( X )
- - 4
FICURE
-
STATIC -
LOAD ELONGATION OF A
LOAD BEARING AS SEnBI-Y,
WOVEN TAPE CONCEPT
REPORT NO. DR 5893 PAGE

WEBER AIRCRAFT
ELONGATION (%I
Pmm!u
DYNAMIC LOAD -BUlNGATION OF A
LOAD BIARfNG AS S m L Y ,
WDVBlJ TAPE C(MCEPT
REPORT NO. DR 309.3

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE br COMPANY. INC.
r--
am-
3.2.2 Tensile Testing of Camp~si,t~e

Lowi Bea,-kg Verhers - Con:.
I n t h e dynemic t e s t (Figure 5) performed on a high speed
p i s t o n t e s t e r , i t i s n o t pooeible t o i n t e r r u p t the t e s t
a t a predetermined load l e v e l , s o h e r e i t i s seen t h a t t h e
load continued beyond t h e point where t h e nylon back-up
members pick up t h e load, a s evidenced by t h e sharply up-
turned p o r t i o n of t h e load-elongatic! curve a t t h e end of
t h e loading period.
M a t e r i a l s Research
Three m a t e r i a l s were r e l e c t e d f o r a v a l u a t i o n a s p o s s i b l e
candidates which would e x h i b i t t h e high impact h y s t e r e .
c h a r a c t e r i e t i c s required fo: th2.s system concept. Theae
were undrawn nylon, heat-shrunk Dacron and formic a c i d
t r e a t e d nylon.
A l l t h r e e m a t e r i a l s a r e known t o have r e l a t i v e l y high s t a t i c
r u p t u r e elongation. I n t h i s program they were subjected

t o both s t a t i c and high speed dynamic t e s t i n g s o t h a t
s e l e c t i o n of a m a t e r i a l with a p r e d i c t e d s e n s i t i v i t y t o
r a t e - o f - s t r a i n i n g could be made baaed on t e s t r e s u l t s i h i c h
simulated t h e uue c o n d i t i o n r a t e of s t r a i n i n g .
REPORT NO. 2 5893 PAGE 23

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE 81 C O M P A N Y . INC
3.2.3 M a t e r i a l s Research - Cont.

Concurrent s t u d i e s e v a l u a t i n g t h e p r o p e r t i e s of t h e t h r e e
and a c t u a l
candidate m a t e r i a l s were conducted i n yarn f ~ m
weaving t r i a l s . Weaving t r i a l s a r e of p a r t i c u l a r importance
i n regard t o t h e undrawn nylon m a t e r i a l s because of t h e i r
tendency t o elongate when placed under tension. In nomal
t e x t i l e processing yarns may be placed under tensions during
t h e preparation of warps and again, during weaving. There-
f o r e a c t u a l weaving t r i a l s of t h e s e elongation s e n s i t i v e
m a t e r i a l s were made t o allow a study of processing e f f e c t s
on yarn e v a l u a t i o n t e s t s .
A d e s c r i p t i o n of tapes and braiGs f a b r i c a t e d from undrawn
nylcn f i b e r s follows:
Type -Warp Filling

PWC 2 (2" wide) 36 ends 25 picks
Sateen weave 965 d e n i e r Dupont 965 d e n i e r Dupont
N-13 nylon N-13 nylon
PWC 3-2 (braid) 4 ends per supply package116 c a r r i e r s

63 denier113 filament Chemstrand
high elongation nylon
PWC 3-1 (braid) 1 end per c a r r i e r 1 8 c a r r i e r s

965 d e n i e r N-13 Dupont nylon
PWC 4-1 (2" wide) 112 ends 30 picks

Sateen weave 965 d e n i e r Dupont 965 d e n i e r Dupont
PWC 4-2 (2" wide) 112 ends 35 picks

Sateen weave 965 denier Duront 965 d e n i e r Dupont
'EPORT NO. DR 5893 PAGE 24

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & C O M P A N Y . INC.
3.2.3 M a t e r i a l s Research - Cont,

Undrawn and P a r t i a l l y Draw Nylon
Undrawn and p a r t i a l l y drawn nylon exhib i t unrecwerec
extension, hence hye t e r e t i c energy absorp tion, when
subjected t o t e n s i l e loading. Samples of duPont Type N-13
undrawn nylon yarn were obtained and t e s t e d t o determine
s u i t a b i l i t y a s an energy-absorbing m a t e r i a l .
Samples of t h i s m a t e r i a l were subjected t o t e n s i l e t e s t s ,
using a standard I n s t r o n t e s t e r f o r conventional slow
speed s t a t i c t e s t s , and a dynamic t e n s i l e t e s t e r t o o b t a i n
test d a t a f o r high speed loading conditions. Static tests
were perfomed a t j a v speeds of 20 inches per minute.
Dynmic tests were performed a t draw r a t e s of 30 f e e t
p e r second.
Additional samp-2s o f t h e undrawn nylon yarn were then
subjected t o varying degrees of drawing, using both h o t
tind cold drawing techniques. These samples were then
subjected t o both s t a t i c and dynamic t e n s i l e t e s t i n g .
A summary of t h e t e n s i l e t e s t d a t a f o r a l l of t h e s e
m a t e r i a l e i s t a b u l a t e d i n Table 3.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY. I N C .

TABLE 3
TENSILE TEST DATA OF N-13 NYLON YARN

(965 -'denier;
.. . .- --.-
- .
-
34 . filament;;)
Static Dynamic
I n s t r o n a t 20f'/min 30'/sec
2 inch gage length 3 inch gage length
Breaking Breaking
Load Elongation Load Elongation
9. gms s,
Control
Drawn 50% a t 7 0 ' ~
a t 370%
Drawn 100% a t 7 0 " ~
a t 365OF
Drawn 200% a t 7 0 ° ~
a t 380°F
Drawn 4002 a t 70°F
a t 370'~
REPORT NO. DR 5893

-- PAGE 26
3.2.3 Materiala Re,darch - Cont.
Heat-Shrunk Dacron
Certain types of Dacron yarns when exposed t o elevated
temperatures s h r i n k considerably, r e s u l t i n g i n materials
which posseas g r e a t e r energy-absorbing c a p a b i l i t y through
higher elongations t o break. Samples of Type 52 (110
d e n i e r ) Dacron yarn, and Type 5?00 (220 d e n i e r ) yarn were
s u Y ~ j e c t e tdo thermal treatments, and then t e s t e d both
s t a t i c a l l y and dynamically t o determine s t r e n g t h and
elongation p r o p e r t i e s . R e s u l t s of t h e s e tests a r e
summarized i n Table 4.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY. INC.
BURSANK, CALIFORNIA 91 503

TABLE 4
TENSILE
-. - TEST DATA OF DACRON YARNS
Static
I n s t r o n a t SW/min
5 inch gage length 3 inch gage length 1
Breaking Breaking
Load Elongation Load Elongation
ma a grns X
Type 52 (11CO d)
Treated a t 350'~ f o r 2 min 7850 33 5992 26
i
I Treated a t 4 0 0 ~f o~r 1 min 8172 50 5 600 33
' Type 5100 (220 d)

I Treated a t 350% f o r 2 min 1362 36 1378 25
'
!
Treated a t WOOF f o r 1 min 1285 47 1200 41

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE & COMPANY, I N C .
3.2.3 Material8 Research - Cont.

Formic Acid Treated Nylon
E a r l i e r w r k h a s shown t h a t drawn nylon yarn shrunk i n
formic a c i d s o l u t i o n e x h i b i t e d high e l o n g a t i o n p r o p e r t i e s .
For t h e present work, a d d i t i o n a l experiment8 were performed
using a 59% c o n c e n t r a t i o n throughout, with varying tempera-
t u r e and r e a c t i o n t i m e t o determine a treatment formula

which would p r w i d e a shrunk nylon with opi:imum p r o p e r t i e s .
R e s u l t s of t h i s series of t e s t s a r e given i n Table 5.
REPORT NO. 5893 PAGE 29

WEBER AIRCRAFT
DIVISION OF N > L T E R KlDDE & COMPANY. INC.
3.2.3 Materials Reaearch - Cont.
TENSILE TEST DATA OF FORMOC ACID -TED hnON YARNS
Static Dynrmrtc
I
I n s t r o n a t 5"/min
5 inch gaga length
I Breaking
30 ' / aec
3 inch gage length
Breaking
I
I load ElongarAon Laad Elongation i
gms Z z
I
-
I
I Control (Type 300
Nylon 55, 210-34-1-2)
!
j 1669 18.9 1700 13.3 i
I
i Treated 59% HCOOH a t

31°c f o r 15 min ! 1397 45.4 1580 40
Ii
! 1
j Treaced 59% HCOOH a t
; 6 6 ' ~ for 7-112 min 1050 112.4 603 101 1
I
1 Treated 59% HCOOH a t
, SO'C f o r 2 min 1373 64 1135 52
Treated 59% HCOOH a t ' I

1
1
60'5 f o r 2 min 1202 79 1135 72 !
I
I

WEBER AIRCRAFT
2.2.3 . a t e r i a l s Research
M - Cont.
F r w these experiments one scanple appeared superior t o a l l
o t h e r s with regard t o t h e d e s i r e d impact t e n r i l e behavior.
1Ms was t h e formic a c i d - t r e a t e d Type 300 nylon yarn t r e a t e d
a t 6 6 ' ~ f o r 7% minutes. Another p o t e n t i a l candidate was
the Type 5100 Dacron, heat-relaxed a t 4 0 0 ~ ~ However,

. the
r u p t u r e e x t e n s i b i l i t y of t h e Dacron vaa r a t h e r low and i t s
general s t r e s s - s t r a i n curve shape waa n o t a s good a s t h e
formic a c i d - t r e a t e d nylon. The drawn N-13 yarns weme
extremely v a r i a b l e and were eliminated from f u r t h e r consicar-
ation. Figure 6 shows t h e stress s t r a i n curves f o r t h s a e
t h r e e m a t e r i a l s when t e s t e d a t 30 feet-per-second draw
rates.
As seen i n Figure 6 t h e formic a c i d - t r e a t e d nylon i s more
d e s i r a b l e because i t s e t r e s s - s t r a i n curve shows a more
n e a r l y f l a t post-yield s l o p e a t a reasonably high sustained
load l e v e l . This promises a l a r g e p o t e n t i a l f o r h y ~ t e r e t i c
energy absorption wer t h e long e l m g a t i o n range required by
t h e geunetry of t h e couch cross-section.

WEBER AIRCRAFT
3.2.3 Materials Rererrch - Cont,
-Type 5100 Dacron

Heat Relaxed a t
Formic Acid Treated

Nylon 60°c, 2 Minuter
ELONGATION ( X )
TESTED AT 30 FEET Pm SECOND

WEBER AIRCRAFT
-
M a t e r i a l s Research - Cont.
Based on t h e test r e o u l t s of formic a c i d t r e a t e d y a m s
t h i s treatment technique was extended i n t o woven m a t e r i a l .
Twu tapeo had been woven c o n c u r r e n t l y with y a m s t u d i e s
t h a t were constructed of nylon warp and f i l l i n g m a t e r i a l s
t h a t would be unaffected by t h e acid treatment, Construct-
i o n of t h e s e t a p e s r e q u i r e d warp yarn8 t o be of a n a t u r e
t h a t would r e a c t t o t h e formic a c i d shrinkage and f i l l i n g
yarns t o be r e l a t i v e l y i n e r t t o t h e formic acid. In
a d d i t i o n , t h e mechanical P-ppearance o f t e x t u r e of t h e s e
tapes had t o b e s o designed t o a l l o w f o r shrinkage i n t h e
longitudinal direction. A r e l a t i v e l y open design was
u t i l i z e d f o r t h i s purpose. For i n i t i a l t e s t i n g , two t a p e s
were woven.
Tapes Warp Filling
PWC 4-3(9/16I1 wide) 50 ends 3011

Sateen Weave 100 denier134 f i l 65135% Dacron/cot ton
Type 300 nylon yarn, & pickulinch
!I
PWC 4-4 (9116" wide) 50 ends 3011

Sateen Weave 100 denier134 f i l 65135% Dscron/cotton
Type 300 nylon yarn, 88 p i c k s l i n c h

WEBER AIRCRAFT
DIVISION OF' WALTER KlDDE & COMPANY. INC.
BURBANK, CALIFORNIA 91 5G3
Material R e e e u c h - ant.
Formic a c i d treatment of theee two woven tapee produced
r e r u l t r runewhat d i f f e r e n t from treatment of t h e yarn,
which was expected due t o d i f f e r e n c e s of shrinkage r e s t r a i n t
imposed by t h e geometry of t h e woven s t r u c t u r e . Evaluation
of theee t r e a t e d tapee ruggested a design modification
which would be more s t a b l e during t h e acid treatment. The
added e t a b i l i t y of ,. .i , tape was achieved through t h e use

of a balanced weave c o n s t r u c t i o n which i s a 4 over 4 twill
weave a s opposed t o t h e 7 over 1 s a t c z n weave used on t h e
p r i o r type. I n addition, t h i s t a p e had a eelvage woven
using edge wires which produce a longer l e n g t h of f i l l i n g
yarn r e s u l t i n g i n reduced r e s t r a i n t d u r i n g warp shrinkage.
T e n s i l e t e s t r e r u l t e on t h e t a p e s a r e given i n Table 6.

WEBER AIRCRAFT
DIV9510N OF WALTER KlDDE & COMPANY. INC.
3.2.3 K a t e r i a l e Research - Cont.

TABLE 6
TENSILE TEST DATA OF FOE-C_c_ACID2YTll NYLON.- TMES
Static Dynmic
t - -1
30 ' /min
I
I n s tron a t O1'/miri
2 inch &age length 3 inch gage length -
I areaking Breaking
i
I
Load
lbe.
Elongation
X
Load
13s.
Elongation
x
I
I Sample PWC 4-3
I
Untreated
Treated (2 rnin)
,
I
i
1
!
60°c
66Oc
72Oc
78'~
1 37 09
28.9
14.5
Brittle
!
!
Sample PWC 4-4
I
I Untreated
I
j Trebted (2 min)
46.7
36.6
21.5
Brittle
Sample PWC 5-1
2 min - 60'~
, --
Based on thto d m t l o p e d data PWC 5-1 webbing was s e l e c t e d
f o r use a s t h e energy absorbing m a t e r i a l i n t h e body support.
REPORT NO, DR 5893 PAGE 35

WEBER AIRCRAFT
DIVISION OF WALTER K I D C Z & C O M P A N Y . I N C
Braided Cord, Knitted Construction Concept
This concept was f ,bricated by Somyk, Incorporated,
Lincoln, Rhode I s l a n d under c o n t r a c t t o Weber k i r c r a f t .
Based upon p r i o r experience i n t h e development of n e t type
body supports f o r t h e hercury s p a c e c r a f t , work p r o c ~ e d e d
d i r e c t l y i n t o t h e c o n s t r u c t i o n o f t h e 5ody support u t i l i z i n g
"Somykord" i n a k n i t t e d construction.
The general c h a r a c t e r i s t i c s of t h e nylon cords and t h e
f a b r i c s , i n physical appearance, a r e t h e same a s re2orted
i n References 4 and 5. The c o r d s a r e braided from s i x
yarns i n such a f a s h i o n as t o e l i m i n a t e t h e c e n t e r hole
which i s c h a r a c t e r i s t i c itl most cord c o n s t r u c t i o n s . The
f a b r i c was h i t t c d i n a loop p a t t e r n designed t o d i s t r i b u t e
t h e non-uniform load of t h e human body elements such thr:
equal displacement f o r t h e body members occurs a t a l l load
levels.
The net was f a b r i c a t e d t o t h e i n t e r n a l s i z e of t h e frame-
w r k with a 3/32 d i m e t e r a i r c r a f t c a b l e encased a l l around
t h e t o t a l periphery of t h e net. The n e t was assembled on

t h e frame-work by hand l a c i n g around t h e a i r c r a f t c a b l e and
through l a c i n g h o l z s i n he couch frame. me l a c i n g h o l e s ore
REPCRT NO. - DR 589.1

WEBER AIRCRAFT
DIVISION OF WALTER KIDDE & COMPANY. INC.
RURBANK, CALIFORNIA 91 503
3-3 Braided Cord Knitted Construction Concept - Cont.

spaced about 1.0 i n c h a p a r t a l l around t h e couch frame.
A s k i r t arrangement with cable, located a t t h e apex of t h e
thigh-torso platform i n t e r s e c t i o n , was used t o a s s i s t i n
p u l l i n g t h e n e t t o t h e required shape.
After s t r e t c h i n g t h e n e t t o "drim-head" t i g h t n e s s by l a c i n g
t o t h e couch frame, a s a t e e n w e n f a b r i c was a t t a c h e d t o
t h e frame by e l a s t i c rubber t i e downs. I'he purpose of the
s a t e e n f a b r i c was t o produce a known f r i c t i o n c o n d i t i o n
be teen t h e couch occupant and net.
Construction
The n e t was k n i t t e d from braided cords made from yarns
of s e v e r a l d e n i e r s a s shown i n Figures 7 & 8.
REPORT NO. 5893 PAGE

WEBER AIRCRAFT
PAGE 38
WEBER AIRCRAFT
3.4 Twisted Cord, Filament Wound

Construction Concept
This concept was f a b r i c a t e d by t h e United S t a t e s Rubber
Company Research Center, Wayne, New J e r s e y , under c o n t r a c t
t o Weber A i r c r a f t and has been s e l e c t e d as t h e concept
which w i l l be used f o r t h e remainder o f t h e Couch Develop-
ment Program.
Based on p r i o r experience, i t was decided e a r l y i n t h e
program t o u s e an a v a i l a b l e 750 d e n i e r , 16 f i l a m e n t ,
z e r o t w i s t , Nylon 6 undrawn y a r n f o r c o n s t r u c t i n g t h e
couch platform, The m a t e r i a l was s u p p l i e d by A l l i e d
Chemical Company and i s coded BWS 13,
Consideration was g i v e n f o r i t s use i n t h e following four
ways :
a. As r e c e i v e d
b. Predrawn l O O % t o 375 d e n i e r (yarn)
c. As 3 p l y 13/13, S / Z c o r d t w i s t e d t o 2668 d e n i e r
d. Cord (c) predrawn 1007. t o 1350 d e n i e r
As a r e s u l t o f experiments, i t was Found t h a t t h e predrawn
yarn ( c o n s i d e r a t i o n 'b" above) c o u l d not be t w i s t e d t o make
a sat i s f a c t o r y c o r d ( c o n s i d e r a t i o n "d") .
I n s t r o n s t r e s s - s t r a i n curves f o r constructLons a, c and d
above are shown i n F i g u r e 9. The s i n g l e p l y untwisted
yarn e x h i b i t s t h e h i g h e s t u l t i m a t e s t r e n g t h while t h e 3

Con t ,
--
I
REPORT NO, DR 5893
"- - I .
PAGE 41
WEBER AIRCRAFT
D I V I S I O N O F WALTER K l D D E & C O M P A N Y . I N C
3.4 Filament Wound Concept (cont inued)
p l y t w i s t e d c o r d e x h i b i t s t h e l o n g e s t and most s t a b l e draw
characteristics. The u l t i m a t e e l o n g a t i o n of predrawn c o r d
i s c l o s e l y r e l a t e d t o t h e p e r c e n t t o which i t i s predrawn.
A l l constructians exhibit a considerable inkerent safety
f a c t o r i n u l t i m a t e breaking stress above t h e i r b a s i c draw
stress.
Various a t t e m p t s were made t o e s t a b l i s h t h e s t r e s s - s t r a i n
c h a r a c t e r i s t i c s o f t h e above f i l a m e n t c o n s t r u c t i o n s at
high r a t e s o f e l o n g a t i o n . While no formal documentary
evidence of t h e r e l a t i o n s h i p was obtained, a l l of t h e
fragmentary r e s u l t s suggested t h a t t h e s t r e s s - s t r a i n
p r c ~ e r t i e so f t h e y a r n are e s s e n t i a l l y r a t e independent.
The I n s t r o n developed s t r e s s - s t r a i n r e l a t i o n s h i p was used,
t h e r e f o r e , f o r d e s i g n i n g drop t e s t samples and, u l t i m a t e l y ,
t h e couch platform.
As w i l l be d e s c r i b e d i n g r e a t e r d e t a i l l a t e r , t h e drop
t e s t samples were c o n s t r u c t e d i n i t i a i l y o f t h e 750 d e n i e r ,
u n t w i s t e d and undrawn nylon yarn a s received. The I n s t r o n
s t r e s s - s t r a i n c u r v e on which t n e c a k a l a t i o n s f o r t h e s e
samples was based i s shown as c u r v e (1) on Figure 10. It

was l a t e r learned, however, t h a t t h e drop test r e s u l t s
r e l a t e d more c l o s e l y t o c u r v e (2) on t h e F i g u r e 10 and
REPORT KO. DR 5833 PAGE 42

(1) T e s t e d D i r e c t Fran T e x t i l e Lab,
(2) T e s t e d D i r e c t Fran T e x t i l e Lab.
(3) T e s t e d S a t u r a t e d With Moisture
* Test Terminated
ELONGATION (%)
FIGURE 10
STRESS-STRAIN V A R I A T J e S
ON 75 0 DENIER - - P R A W N
NYLON 6 YARN
WEBER AIRCRAFT
3.4 F i L n e n t Wound Concept - Cont.

t h i s l a t t e r c u r v e was used t o deaign t h e couch p l a t f o r m .
The draw stress e x h i b i t e d by curve (2) of approximately
.690 l b s l y a r n end i s 118% of t h e draw s t r e s s of .585 l b s .
e x h i b i t e d by curve (1). Curve (3) on t h i s same f i g u r e
gave t h e f i r s t c l u e as t o t h e cause o f t h e s t r e s s - s t r a i n
i n c o n s i s t e n c i e s encountered.
A c o n t r o l l e d s e r i e s of t e s t s were run t o e s t a b l i s h t h e
q u a l i t a t i v e e f f e c t o f atmospheric m o i s t u r e c c n t e n t on t h e
s t r e s s - s t r a i n r e l a t i o n s h i p of Nylon 6 undrawn yarn. The
r e s u l t s a t e p l o t t e d on F i g u r e 11. Another s e r i e s -
e s t a b l i s h i n g t h e e f f e c t of temperature - is plotted on
F i g u r e 12.
The p a r t i c u l a r s t r e s s - s t r a i n d a t a on t h e 2668 d e n i e r 3 p l y
t w i s t e d cord, which i s shown as curve (1) on F i g u r e 13,
was obtained a t t h e eame t i m e c u r v e (2) o f t h e s i n g l e end
yarn was e s t a b l i s h e d . The 3 p l y cord (curve 1) e x h i b i t 8 a
more i d e a l i s t i c s t r e s s s t r a i n curve which wao t h e primary
reason f o r i t s e e l ;tion over a s i n g l e yarn a t t e n u a t i n g
member. Curve (2) i s t h e sane as was i n i t i a l l y s h o w on
F i g u r e 10.
REPORT NO. DR 5893

WEBER AIRCRAFT
3.4 -
Filament Wound Conce~t Cont.
FIGURE 11
EFFECT OF MOISTURE OK S2XESS-STBAIN
OF 750 DENIER UNDBAWN NYLON 6 YARN

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY INC
3.4 -
Filament Wound Concept - Cont.
I
REPORT NO. - DR 5893 - PAGE 46
WEBER AIRCRAFC
DlViSlON OF WALTER KlDDE 81 COMPANY. IWC.
3.4 Filament Wound Concept - Cant.
r
Cord Load (Poundr)

WEBER AIRCRAFT
DIV:SION O F W A L T E R KlDDE & COMPANY. INC
3.4.1 Drop l'estr
I n f i l a m e n t wound c o n s t r u c t i o n each e t t e n u a t i r i g c o r d is
f a s t e n e d at two d i a m e t r i c a l l y o p p o s i t e p o i n t s and t h e
l o a d i n g i s balanced at t h e c e n t e r . Formulae were
developed f o r t h i s s p e c i f i c d e s i g n c o c f i g u r a t i o n t o
e x p r e s s cord a t t e n u a t i o n and g ' s developed i n d i s s i p a t i n g
t h e energy r e l e a s e d i n a n impact.
To v e r i f y e x p e r i m e n t a l l y t h e mathematical t r e a t m e n t o f
t h i s problem, a 112 s c a l e d r o p test w a s s e l e c t e d . This
a p p a r a t u s was designed t o t e s t s h o r t l e n g t h s o f f i l a m e n t
wound f a b r i c s which a r e suspended a c r o s s a frame 112
t h e width of t h e a s t r o n a u t ' s couch frame. The l o a d i s
a p p l i e d through a form s i m u l a t i n g t h e body t o r s o . A
comparison of t h e f u l l s c a l e couch s p e c i f i c a t i o n s v e r s u s
two proposed 112 s c a l e t e s t s p e c i f i c a t i o n s i s sunnnarized
i n Table 7.

WEBER AIRCRAFT
3.4.1 Drop T e s t s - Cont.
TABLE 7
-
PRC?OSED TEST SFECIFICATIONS
7 112 Scale Test S p e c i f i c a t i o n I
F u l l Scale I1
' Test Equiptnent Specifications i Proposal A Proposal B
Suspension Width 20 112" 112 scale 112 s c a l e
Drop form length body length 2 'I 6"
Drop form weight 4 114 # i m h i n 25 112 # 47 112 #

torso section
Drop height 7' 3.5'

I
: Impacting velocity 21.2'1sec. 15'1sec.
Cord s t r a i n r a t e variable > f u l l scale f u l l scale
Approx. max. 12" 6" 6"

. deflection
Approx. max. -g 20 10

WEBER AIRCRAFT
CIVISiON OF W A L T E R KlDDE Llr C:3MPANY. INC.
BURBANK, CALIFORN! "\I 503
3.4.1 Drop T e s t s - Cont.

Using curve (1) on Figure 10 a s the b a s i s f o r t h e design,
a test f a b r i c c o n s i s t i n g of 74 s i n B l e yarn 2 n d ~per inch
was e s t s b l i a h e d a s t h e design b e s t s u i t e d t o meet t h e
proposed rest conditions. The g-loads and atteniiation
a n t i c i p a t e d f o r each of t h e two proposed test cariditions
a r e shown on Figures 14 m d 15 as calculated.
Figure 16 shows t h e ; e s c l t s of 'wo I n s t r o n compression
t e s t s made on t h e 74 end elastomer impregnated filament
wound f a b r i c which were obtained f o r making a d i r e c t com-
parison t o t h e c a l c u l a t e d a t t e n u a t i o n curve shown on
Figure 14. The weight c w f i g u r a t i c n ar,2 sample suspension
frame which was designed f o r t h e drop test was used i n
conjunction with t h e I n s t r o n t e s t e r t o develop t h e experiment-
a l curvee. Again t h e e f f e c t of wetting was detected.
A t o t a l of n i n e 112 s c a l e drop tests were conducted.
Several f a b r i c s , i n c l u d i n g t h e 74 endlinch design, were
t e s t e d with r e s u l t s a s sununarized.in Table 8.
The t a b u l a t i o n below h i g h l i g h t s t h e c o r r e l a t i o n between
mathematical p r e d i c t i o n and test d a t a which w a s a c t u a l l y
achieved.

-- -- - - - --- -- -- . - --
Max g C e v e I.
Frame Width 10.5"
-
Man Width 8 -5"
-
Man Depth 4.75"
Cord Strength 74 ends/inch
- -
Weight o f Mari-4.25 l b / i n c h
Drop Height 84.0"
- v1
Pt
0
a
'z3
00
Displacement (Inches)
FIGURE 14
LOAD
-- ATTBJUATION CURVE FOR TEST
SPECIFTC!!TION, PROPOSAL "A", FILAMENT
WOUND CONCEYZ
WEBER AIRCRAFT
DIVISION OF WALTER KIDL : COMPANY. INC
Stopping Distance 6.37"-
&Load on Model
REPORT NO. 5893 PAGE '2

/' W
.*
/' F
/ - -7'
/ /
./ I
0
nm,
F
n
.m
I
s
3
R
(1) Calculated and Transferred From Figure 10

(2) Non-ravel Impregnant Dried 3 b u r s
(3) Non-ravel Impregnant Dried Overnight
Fabric- 7 4 ends/inch Unidirectional
7 3 0 Denier, Undrawn, Nylon Yarn
Saturated with Elastuner Solution
FIGURE 16
E U C H DEFLECTION CURVES ON
w-SCALP: P U T P ~W ~ B L~1m-g
GPUND CONCEPT
SUMMARY DROP TEST RESULTS
FILAMENT WOUND CONCEPT

- - .- . .
T e s t No. I1 1 3
-- . -.
t
Yarn ends/ i ~ h 74 74 74
l! 2
i n sample
Cord ends/ inch

i n saaple
A r r e s t ing* 4 ! 4.5 4
I
deflection
i n inches i
GD for
* 18.7 l10.2 10.0 10.3 11.0 10.25 10.4 10.17 10.17
arresting Figure 10 L-- -- ( ~ llj i ~- ~ ~ - ~
deflection I
GT recorded 23.5 / 12.5 14.6 10.0 7.43 13.1 10.27 :4.15 14.35
on test ..- ..--. . - .
--- . -
!. . -* ... . .- .- - - - - -- - .- --
r-
---- --. --
Yarn .k*-kk M jrkftjr 'k-
g c % ! ends/in.' 55.0 58.5 48.4 55.6 57.5 57.5 50.8 48.7

U?!U * &* ** *
4uca I
bdmo cord 21.6 23.0 i9.0 21.9 22.6 22.6 19.9 19.1
.n 3 4
a -1) enddin. I
4
---- - - --
*Total of e l a s t i c acd p e w n e n t d e f l e c t i o n s
*Read from c a l c u l a t e d l o a d - a t t e n u a t i o n curve on F i g u r e s 10 o r 11
**Sample yarn o r cord ends X GT/GD
-One yarn end - -392 cord ends
NOTES
- - CONTIWEE ON NEXT PAGE
WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE C?t COMPANY, INC.
BUkBANK, CALIFORNIA 91583
-
TABLE 9 (continued)
General Notes on T e s t F a b r i c s
Test 1 - Yarns were impregnated w i t h e l a s t o m e r s o l u t i o n

which appeared t o have no e f f e c t on u t r e s s - s t r a i n
c h a r a c t e r i s t i c s of f i b e r s .
-2 -
Test Same a s 1.
-
Test 3 Same a s 1.
ast 4 - Yarn ends a d j u s t . Impregnated l i k e T e s t 1..
Test 5 - Twisted cord s u b s t i t u t e d f o r yarn. Unirnpregnated.

Test 6 - S i m i l a r t o T e s t 4 e x c e p t v i t h cemented i n p l a c e
k n i t cove3 . The cover p a r t i a l l y s u s t a i n e d t h e
load.
m
t Z- S i m i l a r t o T e s t 5 w i t h i n c r e a s e d number of cord
ends.
Test 8 - S t a b i l i z i n g cord cenented t o c e n t e r s e c t i o n of t e s t
f a b r i c c a u s i n g a l l ends t o draw e f f e c t i v e l y . Atten-
u a t i n g c o r d s impregnated w i t h e l a s t o m e r which sub-
sequent t e s t s i n d i c a t e d could i n c r e a s e t h e cord
draw s t r e s s up t o 69.. Knit c o v e r p l e a t e d and
tacked t o p l a t f o r m and broke f r e e d u r i n g drop t e s t .
Test 9 - Same as 8 w i t h o u t cover.

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE & CCMPANI'. INC'.
- BURBANK, CALIFORNIA 91 503
3.4.1 Drop T e a t s - Cont,

Yarn Ends i n Yarn Ends i n
Test Fabric Telrt F a b r i c
Predicted using atreas-

s t r a i n r e l a t i o n s h i p shown 74
by F i g u r e 10
Predicted using e t r e s s -
s t r a i n r e l a t i o n s h i p shown 62 6
by F i g u r e 11
Suggested by t e s t r e s u l t s 48.4 t o 58.5
The d i s c r e p a n c i e s between t h e experimental and p r e d i c t e d
o r design f a b r i c s could be explained i n s e v e r a l ways b u t
v e r i f i c a t i m t e s t i n g would have t o be conducted t o p i n i t
down p r e c i s e l y . I n t h e neantime, a d e c i s i o n t o base t h e
couch platrorm d e s i g n on F i g u r e 15 i~ a t l e a s t s h c ~ . t: o~ be
a conservative action.
F i g u r e 17 i e inclcded t o ahow a t y p i c a l loading t r a c e
obtained d u r i n g a 1/2 s c a l e drop t e a t . This p a r t i c u l a r
t r a c a was obtained from Drop T e s t Number 3.
REPORT NO. Mz 5893 PAGE 56

WEBER AIRCRAFT
ClVlSlON OF WALTER K13RE & COMPANY. I N C
IUIBANK, CALIFORNIA 91503
Conditions Per Figure
Li7 lb*
- Free Fall *. 470 MS
FIGURE 17
-.
57
F,rPGRT NO. DR 5893 PAGE
WELPER AIRCRAFT
BURBANK, CALIFORN!A 9: 503
3.4.2 Platform Desin~
The purpose of the first prototype couch platform design
was aiaed primarily at proving out a design concept. Spe-
cifically, it was desired to design a platform which would
support a 90 percentile occupan in the eyeballs-in

!
direction:
a. Without appreciable permanent strain when sub-
iected to a 9-g loading condition, and

b. Without exceeding a 20-g loading condition and
a total attenuation of 12" on decelerating from
an impacting velocity of 30 ft./min.
Calculations showed, .owever, that the best compromise

possible would result in the following:
Cords Ends/ inch g-Load Anticipated
Body In Attenuatinp Fabric With 12" Attenuation*
Upper head 9.3 19.7
Lower head 10.O 20.4
Neck l5 .O 21.2
Upper torso 29.2 17.8
Middle torso 34.7 20.1
Lower torso 54.5 20.O

(including % thigh)
Upper shank 11.8 20.8
(including % thigh!
Mid..le shank 4.0 20.9
Foot 8.4 20.9
* Beyond 1-g loading condition. Total deflection from

taut horizontal net position was calculated to be 13-112".
RE?ORT NO. DR 5893 PAGE 58

WEBER AIRCRAFT
3.4.2 f i a t f o r m Desinn (continued)
Cords were chosen i n p r e f e r e n c e t o y a r n because t h e
v i s t e d c o n s t r u c t i o n t e n d s t o p r o t e c t and c e r t a i n l y make
9
t h e i n d i v i d u a l ff:'.aments involverl l e s s v u i n e r a b l e t o
damage.
F i g u r e 1 8 shows t h e o v e r a l l d e s i g n a s a c t u a l l y assembled
for f u l l scale testing. The a t t e n u a t i n g c o r d s a r e
f a s t e n e d t o t h e s i d e s of t h e couch frame by a r&smping
arrangement. The s t a b i l i z i n g c o r d s a r e cemented o n t o t h e
a t t e n u a t i n g cords. Polymeric e l a s t i c s h e e t i n g i s i n s e r t e d
between t h e a t t e n u a t i n g c o r d s e c t i o n s t o a c h i e v e a one-
piece construction. A two-piece k n i t c o v e r i s l i g h t l y
tacked t o t h e backing t o provide a d e g r e e of comfort and
damage p r o t e c t i o n .
To avoid end damage i t was decided t o suspend t h e a t t e n -
u a t i n g cord from nylon m d s which i n t u r n could be
f a s t e n e d t o t h e frame.

WEBER AIRCRAFT
USBANK, CAVCORNIA 91503
3.4.2 Plrtfdrm b u i g n - Coot.

.u
-
REPORT NO. PAGE 60

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE A COMPANY. INC
---
3.4.2 g l a t form Design (continued)
The s t a b i l i z i n g c o r d s c o n s i s t e d of f u l l y 840 deniei-,
1A0 f i l a m e n t w i t h 112 t w s t , type 300 duPont Nylon. The
law e l o n g a t i o n a t break of t h i s m a t e r i a l i s i d e a l l y
s u i t e d t o i n s u r e a balanced d i s t r i b u t i o n of l o a d i n g t o a l l
the a t t e n u a t i n g c o r d s i n t h e design. Its s t r e s s - s t r a i n
characteristic 1s shown on F i g u r e 19. The s t a b i l i z i n g
c o r d s a r e r e s t r i c t e d t o a p o s i t i o n under t h e body where,
due t o f r i c t i o n , t h e attenuatin!: c o r d s do not e l o n g a t e .
The k n i t cover was k n i t from 8 p l y s of 70 d e n i e r
s t r e t c h a b l e nylon t o a b a l a l x e d c o n s t r u c t i o n of 1 3 wales
and c o u r s e s p e r inch.
QEPORT NO. DR 5893

WEBER AIRCRAFT
DIVISION OF WALTER KIDDE & CDMPANY. I N C .
Elongation ( X )
FIGURE 19
STRESS W N OF
840 DENIER NYLON 300
STABILIZING CORE
REPORT NO. DB 5893 PAGE 62

WEBER AIRCRAFT
3 .5 Summary of Concept Evaluation Test Frogam -

The s t a t i c loads were applied a t 1-8, 3-g, 6-g and 9-g
i
load l e v e l s , and -?turned t o 1-g, with d e f l e c t i o n s of t h e
body support and couch framework recorded a t each step.
The system was h y d r a u l i c a l l - loaded by pressure pads
applying t h e load t o an anthropomorphic dummy a t t h e
c a l c u l a t e d cog. l o c a t i o n f o r t h e v a r i o u s body members.
Dynamic t e s t i n g was conducted a t Weber's dynamic t e s t
stand. The t e s t apecimea was mounted on a s l e d with t h e
dummy properly positioned and a c c e l e r a t e d t o t h e required
parameters by a f a l l i n g hammer s t r i k i n g a s p r i n g plunger
attached t o t h e s l e d c a r r i a g e . By varying t h e hauaner
height, s p r i n g r a t e and g r o s s s l e d weight: d e s i r e d g-levels,
v e l o c i t y changes and o n s e t r a t e s can be imparted t o t h e
specimen.
3.5.1 General Performance
The items under t h i s c l a s s i f i c a t i o n applied t o those
parameters which were n o t d i r e c t l y r e l a t e d t o t h e s t a t i c
o r dynamic performance of t h e systems. The q u a l i t a t i v e
parameters, such a s comfort and pre-shaped contour, are
contained i n t h i s section.
PAGE 63
WEBER AIRCRAFT
DIVISION OF W A L T E R IKIDDE & C O M P A i J Y . INC
3.5-1 General Performance ( c o n t i n u e d )
The t h r e e concepts, tks p r e s e n t e d fcr t e s t , a l l u t i l i z e d
some form of uylon f o r t h e h y s t e r i t i c , energy a b s o r b i n g
material. The woven t a p e system was t h e o n l y one t o

u s e a s p e c i a l l y processed nylon m a t e r i a l . The k n i t t e d
system was b r a i d e d zn machinery which was s p e c i a l l y
designed and c o n s t r u c t e d by t h e manufacturer o f t h a t
system. The t w i s t e d cord from which t h e f i l a m e n t wound
system was c o n s t r u c t e d was t h e o n l y concept u s i n g tech-
niques generally available i n the industry.
The c o r d s used i n t h e f i l a m e n t wound system f o r t e s t were
l i v e l y and r e q u i r e d a c e r t a i n amount of p r e - t e n s i m t o
prevent them from kinking. The k i n k i n g does n o t appear
a s a major problem a s t h i s i s t y p i c a l o f most c o r d s o r
t h r e a d s which are rnachke t w i s t e d . This c h a r a c t e r i s t i c
c a n be removed by chemical, mechanical, o r thennal methods,
depending on t h e end usage of t h e product. Due t o t h e time
l i m i t a t i o n s i n c o n e t r u c t i n g t h e test systems, i t was decided
t o l e t t h e m a t e r i a l kink because p o s t p r o c e s s i n g could
a f f e c t t h e system performance.
The k n i t t e d concept was g e n e r a l l y c o n s i d e r e d t h e most
comfortable a l t h o u g h t h i s parameter was d i f f i c u l t t o
e v a l u a t e because of t h e e x c e s s i v e l y l o n g t h i g h l e n g t h
dimension used i n t h e f a b r i c a t i o n of a l l t h e body s u p p o r t
concepts.
REPORT NO. DR 5893 SAGE 64

WEBER AIRCRAFT
DIVISION OF WALTER KtDDE I% COMPANY. INC
BURCANK, CALIFORNIA 91 503
3.5.1 General Perfonnance - Cont.

The woven t a p e system v a s t h e l e a s t comfortable due t o
t h e high t e n a c i t y o f t h e s t a t i c l o a d t a p e s which could
n o t conform t o t h e l o c a l c o n t o u r l e n g t h of t h e body.
The l o o s e c o n s t r u c t i o n of t h e system r e s u l t e d i n a
f e e l i n g t h a t one might f a l l through t h e n e t and prevented
f u l l c o n c e n t r a t i o n on t h e comfort a s p e c t s of t h e system.
T h i s system however, was t h e o n l y one submitted which
c o u l d be a d j u s t e d t o accommodate t h i g h l e n g t h of an
average occupant. The f a l l i n g through f e e l i n g r a s l a t e r
reduced by adding a cover l a y e r t o t h e system.
The high t e n s i o - f i e l d i n k n i t t e d system prevented
a r t i c u l a t i o n tests o f t h a t system, The n e t was p o s i t i o n e d
on t h e a r t i c u l a t i n g frame such t h a t i t p u l l e d behind t h e
p i v o t p o i n t s on t h e frame which f o r c e d t h e f r m e w o r k t o
t h e open o r closed. p o s i t i o n l i m i t s . The o t h = r tcjo
systems were s a t i s f a c t o r i l y a r t i c u l a t e d and no problems
were d e t e c t e d .
The f i l a m e n t wound system and t h e k n i t t e d system both
weighed i n a.t 2.5 l b s . each. The woven t a p e system
REPORT NC. DR j89.3 PAGE 65

WEBER AIRCRAFT
DIVISION OF WALTER KlODE 5 C O M P A N Y . I N C .
3.5.1 --
General Performance (continued)
weighed 4.3 l b s . The recorded weight was of t h a t p o r t i o n
of t h e body s u p p o r t which was r e p l a c e d d u r i n g t h e dynamic
tests.
The e v a l u a t i o n team determined t h a t t h e f i l a m e n t wound
concept had t h e b e s t g e n e r a l p e r f o m a n c e .
3.5.2 S t a t i c Performance
The s t a t i c l o a d s were a p p l i e d h y d r a u l i c a l l y t o t h e body

s u p p o r t s with t o t a l d e f l e c t i o n s measured a l o n g :he center-
l i n e of t h e simulated occupant a t f i v e p o s i t i o n s ; head,
c h e s t , upper cand lower p e l v i c and shank a r e a s ,
Local e l o n g a t i o n i n t h e f a b r i c s , measured a t c e n t e r l i n e and
outboard p o s i t i o n s a t f o u r (4) s t a t i o n s a l o n g t h e t o r s o ,
were recorded. Couch s t r u c t u r e d e f l e c t i o n s were a l s o
measured f o r p o ~ s i b l el a t e r u s e i n t h e d e s i g n of t h e couch
structure.
Tabulated d a t a p o i n t s a r e p r e s e n t e d i n Reference 6. The
s t a t i c d e f l e c t i o n s a r e averaged and stmnnarized i n Table 9.

WEBER AIRCRAFT
DIVISION OF W 4 L T E R KlDDE & COMPANY. lNC
3.5.2 - a t i c Performance - Cont.

S t-
TABLE 9
-
AVERAGE STATIC LOAD DEFLECTIONS,
-- --- S W Y
Parmeter Spec Allowable Wwen Tape Knitted Filamt- c Wound
Concept Concept Cot:?ep t
0 - 1-g
0 - 9-g
Perm set a t 0.0 * 1.03 1.4

1-8
* S t a t i c load platform f a i l e d a t 3-g. Average d e f l e c t i o n , 1-g
t o 3-8 load was 0.32 inches.
The woven tape concept had a premature r e l e a s e of t h e
e t a t i c load bearing p l a t f o r n (tapee) a t t h e 3 - 4 l o ~ d
condition. Based on the 1-8 t o 3-g load d e f l e c t i o n s t h i s
system probably would have conformed v e l l wL t h i n d e f l e c t i o n
allowables f o r t h e e t a t i c loed t e a t . Investizat?on of
t h e loading conditior., ahowed t h a t t h e c a n t r ~ u rof t h e
dumy did n o t conform t o t h e c i r c u l a r a r c body ~ e c t i o n
assumption ured i n determining t h e atrer,gth of t h e b i g h t
close-out tape. Thie r e s u l t e d i n loading t h e tape a t a
higher r a t e than a n t i c i p a t e d . Re-cvrluation of the loads
based on t h e a c t u a l dumy body aecf.ions could r e s o l v e t h e
problem. See Figure 20 f o r a pho:;ogxaph of t h e t e a t e e t up.
Thc filamenr wound concept had l a r g e r average d e f l e c t i o n s
than t h e k n i t t e d rystem but t h e d e f l e c t i o n was more u n i f o m .
REPORT NO. DE PAGE 67

weem AIRCRAFT
DIVISION OF WALTER KlDDE & C O W P A N Y . INC.
3.5.2 S t a t i c Performance (continued)
A t t h e 9-g load l e v e l t h e maximum d e v i a t i o n of t h e bod!;
members from a uniform d e f l e c t i o n f o r t h e filament wound
system was only 2.1 inches where t h e k n i t t e d system was
3.4 inches.
The e v a l u a t i o n team graded tile filament wound system a s
having b e s t s t a t i c ;erformance c h a r a c t e r i s t i c s .
Dynamic Performance
Three high speed motion p i c t u r e cameras a t 1400 t o 1600
frames p e r second and f o u r accelerometers were used t o
record t h e c h a r a ~ t ~ r i s t i oc fs t h e body support concepts
f o r each t e s t . From t h e movies (Reference 7) i t was
detennined t h a t t h e head and t o r s o of t h e d u m y i n t h e
woven t a p e body support moved uniformly u n c i l the b i g h t
i n t h e e l a s t i c ioad p l a t f o r m was extended causing t h e
head, c h e s t and p e l v i s a r e a s t o bottom cut i n approxi-
mately t h a t order. There were s e w - a 1 energy absorbing
tapep t h a t f a i l e d during t h e impact. The dumnjr rcbound
d i d not appear t o be e x c e s s i v e l y r a p i d o r severe.
The t o r a o mid head d e f l e c t i n g a s a u n i t i s mandatory i n
a system of t h i s type a s r a p i d d i f f e r e n t i a l movements of
t h e head and c h e s r can cause s e v e r e damage t o t h e

WEBER AIRCRAFT
3.5.3 Dvnamic Performance (continued)
c e r v i c a l v e r t e b r a and musculature. Although not as
s e n s i t i v e t h e lumbar v e r t e b r a a r e a l s o s u b j e c t t o t h e
same type o f damage, e s p e c i a l l y f r a c t u r e o f t h e v e r t e b r a l
head.
Lack of uniform body displacement under v a r i o u s loading
c o n d i t i o n s was a major problem w i t h t h e k n i t t e d body sup-
p o r t concept. T h i s prcbably could be c o r r e c t e d by
r e a r r a n g i n g t h e v a r i o u s s t r e n g t h c o r d s i n t h e system.
The movies i n d i c a t e d t h e head, p e l v i s and t h e n c h e s t
r e g i o n s bottomed and a r a p i d rebound was e v i d e n t .
The dynamic d e f l e c t i o n f o r t h e f i l a m e n t wound system was
' h e most uniform of t h e t h r e e systems. From t h e motion
p i c t u r e s i t was s e e n t h a t t h e t o r s o and head responded
a s a s i n g l e , r i g i d mass. The dxsrlacement and rebound

were v e r y uniform and a smooth r e v e r s a l of d i r e c t i o n from
t h e a r r e s t i n g d e f l e c t i o n t o t h e rebound was i n d i c a t e d .
It shoul3 be noted t h a t t h e r e was no a t t e m p t t o r e s t r a i n
t h e dummy i:_ t h e body support once t h e a t t e n u a t i n g
sequence was i n i t i a t e d . P r i o r t o receiving the accelera-
t i o n f o r c e s t h e dummy was p o s i t i o n e d i n a 1-g d e f l e c t i o n
p o s i t i o n t o simulate parachute descent. T h i s loading

WEBER AIRCRAFT
3.5.3 Dynamic Performance - Cont.

was required because t h e dtm~l~y
was positioned i n a back
v e r t i c a l p o s i t i o n due t o t h e s l e d being a c c e l e r a t e d i n a
h o r i z o n t a l plane.
One of t h e most i n t e r e s t i n g c h a r a c t e r i s t i c s noted i n
dynamic t e s t i n g of t h e d i f f e r e n t concepts i s t h a t each
system had a c e r t a i n response and, w i t h i n t h e l i m i t s t e s t e d ,
v e l o c i t y changes (changes i n energy a t t e n u a t i o n l e v e l s )
and body p o s i t i o n produced minor changes i n t h e response
of t h e system. Also, preloading t h e n e t i n s t a t i c
(simulated launch) t e s t s d i d n o t r e s u l t any n o t i c e a b l e
effect.
I n e v a l u a t i n g t h e dynamic performance t h e d a t a obtained
from t h e dtmmy l e g has beec eliminated. Since t h e thigh
length of t h e platforms precluded proper f i t of t h e
drmany's leg, i t i s believed t h a t t h e r e s u l t i n g d a t a
may be misleading.
This problem was resolved during t h e next phase of t h e
development .
I n Table 10 t h e d e f l e c t i o n d a t a has been summarized and
shows ~ n oe v e r a l l dynamic response f o r each concept.
Figure 21 shows t h e t y p i c a l response c h a r a c t e r i s t i c s of
t h e body eupport concepts.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE tk COMPANY. INC
3.5.3 Dynamic Performance - Cont.

TABLE - 1 0
SUIlMARY DYWlIC -DATA
p-.-
SPEC WOVEN TAPE KNITTED CORD FILAMENT

PARAMETER ALLOWABLE CONCEPT CONCEPT WOUND CONCEPT
Body Angle - 66 O LO8 56 O 56 O 66 O
Velocity 30 f p s (max) 24fps 26fps ZOfps L9fps 25fps

Change
Input 50g (max) 69 8-g 55.6-g 55.3-g 52.1-g 65 .0eg

Force
Avg Dumy 20g (max) 23.4-g 23.0-g 32.5-g 20.7-(! 22.9-::

Acceleratior
Avg Dummy 5000gl s e c 688-g /r 529-g/s 1810-g/r 335-g/s 1011-g/s

Rate o f (mad
Acceleratior
Avg Dynamic 9 inch 11.gin L l b 3 i n 6.8in 9.8in 10.3in

Deflection (-1
Maximum 12 inch 13.5in L2.9in LO .gin L2.0in 13.lin
Deflection (-1
S t a t i c br
Dynamic
Region of - Chest Shest Pelvis ?el v i s P e l v i s

Max Defl.
Avg Perm Design

Se t Objective- 4.lin 3.3in L .Oin 2.5 i n 1.8in
9 inches

REPORT NO. # 5893 PAGE 73
WEBER AIRCRAFT
3.5.3 Dynamic Performance (cont iuued)
Reviewing t h e performance of t h e systems it can be seen
t h a t t h o s e w i t h t h e lower dummy a c c e l e r a t i o n response had
a h i g h e r amount of permanent s e t i n d i c a t i n g e x c e l l e n t
attenuating characteristics. The h i g h e r dummy response
g - f o r c e s of t h e k n i t t e d system c:orresponds t o t h e iower
t o t a l d e f l e c t i o n f o r t h e system and i n d i c a t e s t h a t t h e
system may be o v e r designed. T h i s i s f u r t h e r evidenced
by t h e low amount of permanent s e t f o r t,he system.
Reviewing t h e o v e r a l l performance of t h e f i l a m e n t wound
concept one of t h e most o u t s t a n d i n g c h a r a c t e r i s t i c s of
t h e system was t h e u n i f o s u i t y of d e f l e c t i o n .
The spread of high and law f o r c e s and d e f l e c t i o n s recorded
f o r each system can be seen i n Table 11. The varameters
a r e f o r t h e same t e s t c o n d i t i o n s in Table 1 0 .

WEBER AIRCRAFT
3.5.3 Dynamic Performance (continued)

I
TABLE 11
DEVIATION FROM UNIFORbt-DYIAMIC RESPONSE
WOVEN TAPE KNITTED CORD FIlAENT

PARAMETER CONCEPT CONCEPT WOUND CONCEPT
Body P o s i t i o n
Dummy A c c e l e r a t i o n
Dmny Rate of
Acceleration
Dynamic D e f l e c t i o n
Total S t a t i c 6
Dynamic D e f l e c t i o n
Permanent S e t
U n i f o n l i t y of d e f l e c t i o n and f o r c e s i s i n d i c a t i v e t o t h e
p r e d i c t a b i l i t y of material performance f o r a g i v e n s e t o f
conditions. The u s e of mathematical a n a l y s i s as a t o o l
i n d e s i g n i n g a body s u p p o r t i s v e r y e s s e n t i a l t o design-
ing t h e t o t a l system, i n c l u d i n g attachment of body s u p p o r t
t o t h e m e t a l s t r u c t u r e and stress a n a l y s i s of t h e s t r u c -
ture. Being a b l e t o p r e d i c t t h e performance of t h e body
s u p p o r t a l s o e n a b l e s s c a l c models o f t h e system t o be
b u i l t f o r component t e s t purposes. Also, s t r u c t u r e d e s i g n
can proceed on a p a r a l l e l b a s i s w i t h the f a b r i c body
REPORT NO. DR 5893

WEBER AIRCRAFT
3.5.3 Dynamic Performancx (continued)
support thus enabling the total couch system to be devel-
oped in a minimum of time.
The predictability of the filament wound concept is shown
ia Table 12.
U B L E 12
.
PREDICATED VS ACTUAL DUMMY RESPONSE, FILAMENT W0U.W- SO-rJC_EPT
PARAMETXR PREDICATED A.CTUAL

(Average of two tests)
Head Acceleration 20.7-g 19.7-g
Chest Acceleration 19.7-g 21 7-g
Pelvis Acceleration 20 -g 24.1-g
Leg Acceleration 20.9-g 25.3-g
Dynamic 6 Static 13.5 in. 12.6 in.

Deflection (Avg)
Photographs of the evaluation tests of the filament wound
concept are s3own in Figures 22 and 23.
Based on the results of tests and evaluation of overall
understanding and capability, the filament wound concept
was selected as the best of the three oystems submitted.

WEBER AIRCRAFT
4.0 PHASE I - TASK B - DESIGN AND DEVELOPMENT OF COUCH SYSTM

Analysis of a t h r e e couch system and t h e i n t e r f a c e requirements t o
Apollo Comand Module was performed i n o r d e r t o d e f i n e t h e s p e c i f i c
requirements f o r a a i n g l e couch frame t o be designed, f a b r i c a t e d and
tested. A b a s i z dimension drawing, u s i n g e n g i n e e r i n g drawings of t h e
spacecraf t, was e s t a b l l shed t o detennj.:le t h e geometrical l i m i t s o f t h e
system. The Comaand Module liziits were d e f i n e d as ;ell a s t h e space

permissible f o r each couch and t h e suspension s t r u c t u r e . Tncluded
wae t h e space requirements f o r t h e occupants i n r e l a t i o n t o t h e couch
framework. Detail performance c r i t e r i a for t h e couch frame, suspension
s t r u c t u r e and t h e body s u p p o r t - r e s t r a i n t a 6 S ~ b l ywas e s t a b l i s h e d .
M a t e r i a l s of c o n s t r u c t i o n and t h e parameters t o be t e s t e d and test
procedures were e s t a b l i s h e d . D e t a i l s of t h e work perfonned a r e
discussed i n Reference S.
4.1 - - Requirements
Performance
Basic l o a d s f o r t h e couch framework were e s t a b l i s h e d t o t h e
following l i m i t s which a r e u l t i m a t e f o r c e s :
+ 75-g, - 15-g i n t h e X axis [eyeballs i n (+) and o u t (-)I

f 15-g i n t h e Y a x i s ( e y e b a l l 8 l e f t and r i g h t )
-
+ 45-g, - 15 g i n the Z axis
[e y e b a l l s up (-) and down (+)
For h u n c h , l a n d i n g and c r a s h c o n d i r i o n s , t h e couch framework w i l l
be i n a 66' trunk-thigh body p o s i t i o n . The couch assembly, i n c l u d -
i n g t h e frame, body support and restraint system must be capable of
being folded i n t o a minimum volume f o r stowage and simply removed
from t h e suspension s t r u c t u r e . It i s d e s i r a b l e t h a t t h e couches

WEBER AIRCRAFT
BUKBANK, CALIFORNIA 91503
4.1 Performance Reauirements ( c o n t ' d )
b4 i n t e r c h a n g e a b l e from one p a q i t i o n t o a n o t h e r on t h e suspension
structure. A d d i t i o n a l l y , t h e t r u n k - t h t g h a n g l e s h a l l be a d j u s t -
a b l e t o 66O, 108' and t h e 180' p o s i t i o n s .
The body s u p p o r t was t o remain e s s e n t i a l l y t h e same a s s u b m i t t e d
f o r concept ~ v a l u a t i o uexcept t h e e l a s t i c l i m i t of tb.d assembly was
t o be upgraded from a 9-6 launch load tc 16 f 2 - 6 t o s u s t a i c maxi-
mum r e - e n t r y c o n d i t i o n s of t h e Apollo Command Module. T h i s chaage
was n o t t o a f f e c t t h e 20-g a t t e n u a t i n g c h a r a c t e r i s t i c s of t h e
support. The attachment i - l t e r f a c e t o t h e couch frame must permit
simple i n s t a l l a t i o n o n t o t h e couch frame. The d e s i g n c o n s i d e r a -
t i o n s of t h e body s u p p o r t developed f o r t h i s program w i l l be
r e s t r i c t e d t o e y e b a l l - i n f o r c e s o n l y , compatible w i t h t h e a r t i c u i a -
t i o n requirements of t h e couch frame.
An occupant r e s t r a i n t syste:. must be designed t o p r e v e n t L i a i l i n g
of t h e occupant d u r i n g a s s o c i a t e d r e b v ~ n dc o n d i t i o n s a f t e r t h e
i n i t i a l impact a t t e n u a t i o n has been achieved. Additionally the
amount of rebound f e l t by t h e occupant s h c l l be l i m i t e d t o a 10-g
forcc. The o n l y rebound f o r c e t o be c o n s i d e r e d f o r t h i s program
is i n the eyeball-out d i r e c t i o n . M a t e r i a l s s e l e c t i o n and a s a g e
was p r e d i c a t e d on Weber's background e x p e r i e n c e gained i n develop-
i n g escape and s u r v i v a l systems f o r t h e X-20 (Dyna-Soar! and t h e
Gemini s p a c e c r a f t s . The goirerning environmental c o n d i t i o n Mas
t h e use of m a t e r i a l s compatible w i t h t h e oxygen-rich a t m o s p h ~ z e
REPORT NO. DR-5893 PAGE

WEBER AIRCRAFT
DIVISION OF' WALTER KlDDE % COMPANY. INC.
BCRBANK, CALIFORNIA 91 503
4.1 Performance Requirements ( c o n t ' d )
a t reduced p r e s s u r e s . The e f f e c t s of temperature, humidity, vacuum
and r a d i a t i a n on system performance were considered beyond t h e scoFe
of t h e t e c h n i c a l t a s k ; however, t h e e f f e c t s of temperature and
humidity on t h e a t t e n u a t i n g c o r d s o f t h e body s u p p o r t were i n v e s t i -
g a t e d and is d i s c u s s e d i n S e c t i o n 3 . 4 . A d d i t i o n a l l y , common hard-
ware items such a s cadmium p l a t e d n u t s and b o l t s were used and
r e a d i l y a v a i l a b l e polyurethane foam and e s t a n e cements were used on
t h e body s u p p o r t i n a n e f f o r t t o m a i n t a i n program schedule w i t h
r e a l i z a t i o n t h a t usage of a l t e r c a t e m a t e r i a l s may be r e q u i r e d when
t h e system i s designed f o r a c t u a l f l i g h t use.
4.2 Framework Development
From t h e b a s i c dimension l a y o u t s , i t was e v i d e n t t h a t a deep, narrow
s p a c e was a v a i l a b l e f o r t h e s t r u c t u r e 1 s e c t i o n s of t h e couch frame
and t h e n e c e s s a r y suspension s t r u c t u r e . Three f a c t o r s governed t h e
a v a i l a b l e space f o t t h e framework: t h e d e s i r e t o m a i n t a i n t h e p o s i -
t i o n of t h e crewmember, r e l a t i v e t o t h e s p a c e c r a f t , t h e same a s t h e
e x i s t i n g h a r d couch system; maximum crewmember s i z e ; and t h e a c t e n -
u a t i o n f u n c t i o n achieved by t h 2 system i s o b t a i n e d by t h e occupant
moving w i t h r e s p e c t t o t h e f i x e d framework systGm. rhe couch as-
sembly developed t o s e t i s f y t h e s e requirements i s shown i n F i g - - r e 24.
With t h i s c r i t e r i a e s t a b l i s h e d and t h e requirement t h a t each couch
be e a s i l y removed from t h e suspension s t r u c t u r e , t h e couch f r a n e -
work evolved. Ths b a s i c s e c t i o n a l shape o f t h e t o r s o s t r u c t u r e
REPORT NO. DR-5893 PAGE a1

WEBER AIRCRAFT
D I V I S I O N OF WALTER KlDDE & C O M P A N Y . I N C
4.2 Framework Development ( c o n t ' d )
c o n s i s t s o f a r e c t a n g u l a r s e c t i o n c o n s t r u c t e d o f upper and lower
s h e e t metal caps i n t e r - c o n n e c t e d by f l a t s h e e t members. Inside
t h e s e c t i o n is l o c a t e d a "2-member" t o provide a d d i t i o n a l r e s i s -
t a n c e t o t h e inward bending and t o r s i o n a l f o r c e s c r e a t e d by t h e
f a b r i c body s u p p o r t being loaded by t h e occupant.
The requirement o f t h e l e f t - h a n d couch t o move i n t o a docking p o s i -
t i o n ( p e r m i t t i n g t h e p i l o t t o view d i r e c t l y o u t o f t h e s p a c e c r a f t
windows t o guide t h e v e h i c l e d u r i n g t h e f i n a l phases of rendezvous
maneuvers) d e f i n e d t h e head a r e a of framework making i t n e c e s s a r y
t o move t h e s t r u c t u r e i n towards t h e occupant t o c l e a r t h e Command
Module s t r u c t u r e . Because o f t h e c i r c u l a r a r c h shape o f t h e head
beam, t h e s t r u c t u r e was machined from p l a t e s t o c k i n t o a n "H"
shaped s e c t i o n .
Located i n t h e t o r s o framework a r e t h e a t t a c h m e n t p o i n t s o f t h e
couch assembly t o t h e s u s p e n s i o n system. Each couch has t h r e e
p o i n t s f o r a t t a c h m e n t , two a t t h e lower end of t h e "Utl i n t h e h i p
a r e a and one a t t h e t o p o f t h e frame i n t h e head beam f i t t i n g . This
three-point attachment is intended t o s i m p l i f y i n s t a l l a t i o n of t h e
couches by t h e crewmembers d u r i n g z e r o g r a v i t y c o n d i t i o n s . A cross-
beam, j u s t below t h e o c c u p a n t ' s b u t t o c k s i s provided t o r e s i s t t h e
inward bending f o r c e s and s e c t i o n t o r s i o n from t h e body s u p p o r t o f
t h e t o r s o platform,and t o s u p p o r t t h e l o a d s from t h e l e g and t h i g h
s e c t i o n s of t h e couch frame.
REPORT NO. DR-5893 PAGE 83

WEBER AIRCRAFT
4.2 Framework Development ( c o n t ' d )
The l e g and t h i g h s t r u c t u r e s of t h e frame a r e a l s o r e c t a n g u l a r i n
section. The s e c t i o n is c o n s t r u c t e d i n two p i e c e s , a shallow
channel f o r t h e upper cap and a deep channel which forms t h e s i d e s
and t h e bottom of t h e beam s e c t i o n .
Machined f i t t i n g s a r e provided i n t h e s h e e t metal s t r u c t u r e t o
t r a n s m i t t h e loads through t h e s t r u c t u r a l s e c t i o n s i n t o t h e a t t a c h -
ment f i t t i n g s . Incorporated i n t o t h e l e g , knee and h i p j o i n t
f i t t i n g s a r e t h e hinges which a l l o w a r t i c u l u t i o n of t h e frame t o
its various positions. The mechanism which locks t h e l e g s t r u c t u r e
i n t h e 66' and 108' l e g p o s i t i o n s and permits i t t o a r t i c u l a t e t o
t h e i n f l i g h t and stowed p o s i t i o n s i s housed i n t h e h i p j o i n t f i t t i n g
and i s operated by pushing o r p u l l i n g a c o n t r o l handle l o c a t e d on
e i t h e r s i d e of t h e occupant.
For stowage o f t h e couch, t h e t h i g h and l e g s t r u c t u r e s , w i t h t h e
body support a t t a c h e d , f o l d over t h e t o p of t h e t o r s o s t r u c t u r e .
The l e g s e c t i o n f o l d s upon i t s e l f f u r t h e r reducing t h e envelope
s i z e of t h e stowed couch. When stowed, t h e volume s i z e i s approxi-
mately 46.0" x 23.0" x 12.0t', a s shown i n F i g u r e 25. To stow t h e
couch, i t i s necessary f o r t h e crewman only t o loosen a screw on
t h e t h r e e r e s t r a i n t h a r n e s s - t o - i n e r t i b r e e l attachments, f o l d
t h e couch t o t h e stowed p o s i t i o i l ana r e l e a s e t h e l a t c h which locks
t h e couch s t r u c t u r e t o t h e suspension s t r u c t u r e . These o p e r a t i o n s
may be performed by s u i t e d a s t r o n a u t without t h e u s e of t o o l s . Re-

WEBER AIRCRAFT
DIVISION OF WALTER KID3E & COMPANY. INC
4.2 Framework Deve l o p m a ( c o n t ' d)
i n s t a l l a t i o n i s performed i n r e v e r s e o r d e r .
The major o b j e c t i v e i n d e s i g n i n g t h e r e s t r a i n t system was t o o b t a i n
one which d i d n o t encumber t h e u s e r o r r e q u i r e complex r i g g i n g and
adjustment. S e v e r a l methods were i n v e s t i g a t e d and f o r t h e u n i d i r e c -
t i o n a l loading a p p l i c a t i o n i t was determined t h a t a l a p b e l t / 3 h o u l d e r
s t r a p arrangement would a d e q u a t e l y r e s t r a i n t h e t o r s o and a s i n g l e
l e g s t r a p would c o n t a i n t h e lower limbs t o t h e body s u p p o r t .
Anchorage of t h e r e s t r a i n t h a r n e s s is accomplished by f l o o r mounted
inertia reels. The r e e l s a r e used t o t a k e up t h e s l a c k i n t h e h a r -
n e s s d u r i n g a t t e n u a t i o n t o p r e v e n t e x c e s s i v e rebound of t h e crew-
members d u r i n g l o a d r e v e r s a l s . S e v e r a l t e s t s were made w i t h
s t a n d a r d MA-6 r e e l s t o determine t h e time r e q u i r e d t o r e t r a c t twelve
i n c h e s of webbing. It was found n e c e s s a r y t o i n s t a l l a h e a v i e r
r e t r a c t i o n s p r i n g t o reduce t h e r e q u i r e d time from 100 m s t o 60 m s .
T h i s i s r e q u i r e d t o p r e v e n t t h e occupant from rebounding i n t o s l a c k
webbing i n t h e r e s t r a i n t system d u r i n g sudden load r e v e r s a l s . An
a t t e n u a t i n g l i n k of undrawn nylon was provided a t t h e attachment t o
t h e i n e r t i a r e e l s t r a p t o l i m i t t h e f o r c e s e x p e r i e n c e d by t h e occu-
pant d u r i n g rebound t o l e s s t h a n 10-g's. Attachment of t h e body
s u p p o r t t o t h e couch frame i s accomplished by a l i g h t w e i g h t metal
clamp which g r a s p s t h e edge of t h e body s u p p o r t . The clamp has
keyhole-shaped s l o t s on one edge which f i t over and s l i d e under
shouldered screws which a r e l o c a t e d on outboard s i d e of t h e couch

WEBER AIRCRAFT
DIVISION O F WALTER KlDDE 81 COMPANY. INC.
4.2 Framework Development (cont ' d)
frame. They a r e positioned such t h a t t h e inner edge of t h e clamp
n e s t s a g a i n s t a ledge b u i l t i n t o the couch frame s e c t i o n . This
ledge absorbs t h e f o r c e s transmitted by the body support as compres-
s i o n from t h e clamp t o the ledge. The loads i n t o t h e clamp a r e
f u r t h e r reduced by f r i c t i o n l o s s e s due t o t h e body support wrapping
around t h e upper cap of t h e framework a s shown i n Figure 26.
4.3 Body Support and R e s t r a i n t Development
Upon concurrence by the procuring agency of t h e s e l e c t e d concept,
a s p e c i f i c a t i o n was prepared which provided t h e t e c h n i c a l d i r e c t i o n
t o the supplier. This s p e c i f i c a t i o n , Reference 9, provided t h a t
s p e c i f i c a t t e n t i o n i n t h e development of t h e body support and r e s -
t r a i n t system be given t o t h e following items:
a. Development of an a t t e n u a t i o n cord f r e e of a tendency t o c u r l .
b. Upgrade t h e maximum e l a s t i c force from 9 - g t o 16-g without i n -
t e r f e r i n g with t h e 20-g e y e b a l l s - i n a t t e n u a t i n g c h a r a c t e r i s t i c s .
c. Develop a r e s t r a i n t harness capable of r e s t r i c t i n g and l i m i t i n g
t h e eyeballs-out exposure t o a 10-g maximum force.
d. The developed body support t o be capable of being a r t i c u l a t e d
a s a p a r t of the couch frame.
Inherent with t h e development was t h e s e l e c t i o n of m a t e r i a l s com-
p a t i b l e with t h e Apollo mission and t h e development of t o o l s and
REPORT NO. DR- 589 3 PAGE 87

A D ~ v ~ s l oonl Walter Klddc 8 C o m p n r l v , It-c
Burbonk, Col~fornia
I
-.
I
I 4.2 Frmework Developnent - Cont.

I
BODY SUPPORT -
UPPtR
STIUCIUUL
CAP
-?\ )y :' .-
..
-<
,
- SPRING IOCK
- SHOI!I.DERED SCREW
\
NYLON ANCHOR ROD
PICURE 26
Afi.ACHHENT OF BODY SUPPORT TO C3UCH ?*

WEBER AIRCRAFT
DIVISION OF WALTER KlDtE & COMPANY. INC.
4.3 Body Support and R e s t r a i n t Development ( c o n t ' d )
f i x t u r e s necessary t o r e l i a b l y and a c c u r a t e l y assemble t h e u n i t s .
The design which evolved from t h i s development e f f o r t , F i g u r e 27,
was i n f l u e n c e d t o a c o n s i d e r a b l e e x t e n t on t h e need t o supplement
t h e s t a t i c load b e a r i n g c a p a b i l i t y of t h e primary a t t e n u a t i n g c o r d s
w i t h a secondary s u p p o r t i n g system,
E s s e n t i a l l y , t h e primary s u p p o r t i s comprised of s u i t a b l y spaced
undrawn nylon a t t e n u a t i n g c o r d s which e f f e c t i v e l y l i m i t d e c e l e r a -
t i o n r e a c t i o n s on impact. S i u c e a cover ( f a b r i c ) was r e q u i r e d t o
i n t e g r a t e and s h i e l d t h e primary s t r u c t u r a l elements, t h e i n t e g r a -
t i o n of f r a n g i b l e l a c i n g s i n t o t h i s b a s i c p a r t was c o n s i d e r e d a
l o g i c a l s t e p f o r g e n e r a t i n g a secondary s u p p o r t . The f a b r i c
"apron" t h a t i s l i ~ e w i s ei n t e g r a t e d w i t h t h e windings, s a t i s f y t h e
anchor requirements of t h i s supplementary system. The secondary
l a c i n g s a r e proportioned t o supplenent t h e s a f e , non-deformable,
load c a r r y i n g c a p a b i l i t y of t h e primary c o r d s t o w i t h s t a n d t h e
maximum s t a t i c load c a r r y i n g requirements of t h e mission. They a r e
designed t o "break out" a t o n l y s l i g h t l y h i g h e r l o a d s , however, s o
a s n o t t o i n t e r f e r e w i t h t h e load l i m i t i n g a t t e n u a t i n g c a p a b i l i t y
of the primary system a c t i n g on its own. Headrest and l e g s e p a r a -
t o r s were s p e c i f i e d t o complement t h e r e s t r a i n t h a r n e s s t o f u r t h e r
reduce t h e hazard of d i f f e r e n t i a l body member displacements.
4.3.1 Development of Non-Curlinn A t t e n u a t i n g Cord
I n a r e l a x e d s t a t e ( s l a c k ) t h e c o r d s used d u r i n g concept
PAGE 89
* -
REPORT NO. D&-5893 PACE 90
WEBER AIRCRAFT
4.3.1 Development of Non-Curling A t t e n u a t i n g Cord ( c o n t ' d )
e v a l u a t i o n e x h i b i t e d a tendency t o c u r l , making i n s t c l l a t i o n
o n t o t h e couch frame d i f f i c u l t . I n some i n s t a n c e s , t h e c u r l
was s o t i g h t t h a t t h e c o r d s would e l o n g a t e r a t h e r than u n c u r l .
Three c o n s t r u c t i o n s were s t u d i e d t o o b t a i n a cord w i t h low
c u r l i n g tendencies. These comprised:
o B r a i d i n g a c o r d from u n t w i s t e d yarn
e Balancing s i n g l e y a r n twists a g a i n s t t h e assembly t w i s t
@ Backing o f f t h e assembled t w i s t
The b r a i d e d cord was produced on a commercial b r a i d e r w i t h o u t
a f f e c t i n g t h e y a r n ' s drawing c h a r a c t e r i s t i c s , but t h e yarn
s t r a n d s were l o o s e l y combined and h i g h l y s u b j e c t t o damage.
D i f f e r e n t t y p e s of t w i s t e d c o r d c o n s t r u c t i o n s were i n v e s t i g a t e d .
S e v e r a l y a r n t w i s t s and c o r d t w i s t combinations appeared t o
have t h e d e s i r e d p r o p e r t i e s except when c u t , t h e s e v e r e d ends
would unwind f o r s e v e r a l i n c h e s u n l e s s r e s t r a i n e d .
F u r t h e r i n v e s t i g a t i o n determined t h a t 'cords mechanically un-
wound one t o two t u r n s per i n c h were "dead" and d i d n o t p o s s e s s
a tendency t o u n r a v e l when c u t . It i s t h e o r i z e d t h a t e l a s t i c
s t r a i n remaining i n t h e c o r d s a f t e r t w i s t i n g i s removed when
t h e c o r d s a r e unwound. The a d d i t i o n a l s t r a i n caused by t h e
t w i s t i n g p r o c e s s i s r e l e a s e d v i a p l a s t i c flow which d e t e r -
mines t h e number of twists found i n t h e "dead" cord.
PAGE g1
WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY INC.
4.3.1 Development of Non-Curlinn A t t e n u a t i n n Ccrd (cont'd!
The cord s e l e c t e d i~ of 3-ply c o n s t r u c t i o n t w i s t e d 13.5 t u r n s
per inch and mechanically unwound t o 12 t u r n s per inch. A
750-denier undrawn nylon 6 yarn was used. The draw p r o p e r t i e s
of t h i s c o r d a r e e s s e n t i a l l y t h e same a s t h o s e used during t h e
concept e v a l u a t i o n phase of t h e program and is shown i n s t r e s s -
train diagram i n Figure 28.
4.3.2 Development of S t a t i c Load C a p a b i l i t y
A s p r e v i o u s l y s t a t e d , t o upgrade t h e e l a s t i c s t n L i c load
b e a r i n g c a p a b i l i t y of t h e system, i t becams n e c e s s a r y t o i n t e -
g r a t e i n t o t h e s u p p o r t a f r a n g i b l e cord s t r u c t u r e t o comple-
ment t h e e l a s t i c c h a r a c t e r i s t i c s of t h e a t t e n u a t i u g cords.
The s h o r t term c r e e p p r o p e r t i e s of t h e a t t e n u a t i n g cord were
investigated, The tests i n d i c a t e d t h a t c r e e p f o r s h o r t i n c r e -
ments of time (launch o r r e - e n t r y c o n d i t i o n s ) would be incon-
sequential i f the attenuating cord is subjected t o s t a t i c
loads e q u a l t o o r l e s s than 60% of t h e c o r d ' s i n h e r e n t draw
stress.
Three c o r d s wera c o n s i d e r e d f o r use a s t h e f r a n g i b l e l a c i n g
t o complement t h e a t t e n u a t i n g c o r d s i n s u s t a i n i n g t h e 16-g
s t a t i c load; a two-ply t w i s t e d dacron c o r d , a two-ply t w i s t e d
nylon c o r d and a four-ply b r a i d e d nylon cord. A l l were made
of 840 d e n i e r high t e n a c i t y f i b e r s .
A f t e r i n v e s t i g a t i n g t h e p r o p e r t i e s o f each c o r d , t h e dacron
PAGE 92
C-
W
..
'-t
WEBER AIRCRAFT
4.3.2 Developmmt of S t a t i c Load C a p a b i l i t y ( c o n t ' d )
cord was s e l e c t e d because of i t s s l i g h t s t r e n g t h advantage
over f u l l y drawn nylon and i t s h i g h e r c o r d modulus.
4.3.3 P r o p e r t i e s of Cover F a b r j g
The inajor f a c t o r s of importance i n t h e s e l e c t i o n of t h e cover
f a b r i c were i t s d u r a b l e appearance, high modulus i n t e n s i o n
and i t s c o n t a c t comfort. Seven nylon canvas f a b r i c s were ex-
amined and a Wellington S e a r s f a b r i c number S/SN-260R was
s e l e c t e d as b e s t s a t i s f y i n g t h e requirements f o r t h i s program.
The m a t e r i a l was dyed and t h e c e n t e r p o r t i o n of t h e cover was
laminated t o a 0.09" t h i c k polyurethane foam backing t o i n -
c r e a s e t h e comfort l e v e l of t h e body s u p p o r t .
4.4 Body Support Desipn
With t h e key elements of c o n s t r u c t i o n f o r t h e body s u p p o r t determined,
t h e y were n e x t assembled i n t o a composite s t r u c t u r e . The p r o p e r t i e s
of each element, a t ambient c o n d i t i o n s a r e a s noted:
A t t e n u a t i n g Cord - Draw S t r e s s - 1.85 l b s .

Elastic Limit
(Creep) - 1.11 l t s .
F r a n g i b l e Lacing - Load t o Break - 29.2 l b s

Elongation
a t Break - 309.
Covering M a t e r i a l - Load t o Break

Elongation a t
- 696 l b s l i n .
Break - 28.5%
D i s t r i b u t i o n o f t h e a t t e n u a t i n g c o r d s was c a l c u l a t e d p r e d i c a t e d on
REPORT NO, DR-5893 - PACE 94

WEBER AIRCRAFT
BURBANK, CALlFCRNlA 91 503
4.4 Body Support Design ( c o n t ' d )
t h e a c t i v e c o r d l e n g t h s , t h e s p e c i f i e d body mass d i s t r i b u t i o n of t h e
occupant, and t h e c r o s s - s e c t i o n a l p r o f i l e of t h e occupant. With t h e
a i d of a computer, t h e energy absorbed by a p r e - s e l e c t e d number of
a t t e n u a t i n g c o r d s was summarized i n c r e m e n t a l l y u n t i l i t e q u a l l e d t h e
i n p u t energy of t h e occupant f o r each s u b - s e c t i o n of t h e s u p p o r t p l a t -
form. Each s u b - s e c t i o n i s a l e n g t h of body support/occupant/couch
frame which has n e a r l y c o n s t a n t g e o m e t r i c a l p r o p e r t i e s .
Based on t h e geometry, t h e changing c o r d l e n g t h s f o r each d e f l e c t e d
p o s i t i o n were e s t a b l i s h e d and t h e s t r e s s l e v e l determined from the
s t r e s s diagram of t h e cord. T h i s d e f i n e d a s t - n d a r d curve f o r each
sub-section. A common d e s i g n d e f l e c t i o n f o r t h e e n t i r e system was
s e l e c t e d and t h e i n i t i a l l y approximated cord d i s t r i b u t i o n was ad-
j u s t e d t o a c h i e v e an energy balance c o i n c i d e n t w i t h t h i s d e f l e c t i o n .
The r e s u l t s of t h i s a n a l y s i s a r e shown i n Table 13.
PAGE 95
WEBER AIRCRAFT

WEBER AIRCRAFT
4.5 Procedure . f o r - C a l c u l a t i n g F i l a m e n t
Wound E n e r ~ yAbsorbing Cord . i s t r i b u t i o n
The f i l a m e n t wound couch i s d e s i g n e d t o s u p p o r t t h e v a r i a b l e w e i g h t
o f a n a s t r o n a u t w i t h a compensating c o r d d i s t r i b u t i o n p a t t e r n .
M a t h e m a t i c a l l y , t h e e n e r g y a b s o r b e d by t h e c o r d s a t a compromised
d e f l e c t i o n i s made e q u a l i n c r e r n e c t a l l y w i t h t h e i m p a c t i n g ( p o t e n -
tial) P I. : 7~ 3f t h e a s t r o n a u t o v e r t h e e n t i r e l e n g t h o f h i s body.
The e n e r g y a b s o r b e d by t h e c o r d s i s e x p r e s s e d a s :
where N, = number o f c o r d s p e r i n c h i n t h e s e c t i o n o f
couch u n d e r c o n s i d e r a t i o n
li = c o r d l e n g t h a t t h e s t a r t of a n i n c r e m e n t o f
deflection i n feet
lii = c o r d l e n g t h a t t h e end o f t h e i n c r e m e n t o f
deflection i n feet
S i , Sii = c o r d s t r e s s a t i n c r e m e n t s o f l e n g t h l i 2nd l i i
r e s p e c t i v e l y i n l b s . r e a d from s t r e s s - s t r a i n
c u r v e of c o r d .
The i n p u t o r i m p a c t i n g e n e r g y of t h e a s t r o n a u t ' s body i s e x p r e s s e d
a3:
Eb = M ( h f + A ' q)
(2)
where M = mass i n l b s . p e r i n c h a l o n g body o f t h e s e c t i o n
under c o n s i d e r a t i o n .
hf = e q u i v a l e n t f r e e f a l l i n g h e i g h t o f body i n f e e t
based on v e l o c i t y a t moment o f impact.
"{PORT NO. DR-5893 PAGE 97

WEBER AIRCRAFT
DIVISION OF W A L T E R KIDDE & C O M P A N Y . INC
4.5 Prpcecjure f o r C a l c u l a t i r n - F i l a m e n t
Wound Energy Absorbing Cord D i s t r i b u t i o n - Cont.
A = p r e s e l e c t e d d e f l e c t i o n increment i n f e e t chosen t o
summarize t h e e n e r g i e s i n v o l v e d .
q = number of increments involved f o r t h e c o r d l e n g t h
'ii
To c a l c u l a t e t h e c o r d d i s t r i b u t i o n f o r a couch, t h e l a t t e r i s
d i v i d e d i n t o s e c t i o n s which s c p p o r t reasonably uniform p o r t i o n s of
the body a s r e g a r d s weight d i s t r i b u t i o n and shape. A rough e s t i m a t e
of t h e c o r d s / i n c h r e q u i r e d i s t h e n o b t a i n e d by t h e formula
where Sd i s t h e i n h e r e n t s t a b l e draw s t r e s s of t h e c o r d used. With
t h e s u p p o r t i n g c o n f i g u r a t i o n (which w i l l be d i s c u s s e d l a t e r ) , t h e
approximated Nc, M , a s e l e c t e d A and t h e r e s t r a i n t c o r d ' s s t r e s s -
s t r a i n diagram e s t a b l i s h e d ; Ec and Eb a r e summarized w i t h a computer
f o r each couch s e c t i o n u n t i l t h e former exceeds t h e l a t t e r by s e v e r a l
increments of d e f l e c t i o n . Numerous v a r i a b l e s a r e s i m u l t a n e o u s l y
p r i n t e d o u t i n c l u d i n g t h e c o r d s u p p o r t a n g l e , 9 , lii, A q , . lii - 1
l
or X c o r d e l o n g a t i o n , Sii and t h e g-load being experienced.
A t t h i s time, t h e t o t a l d e f l e c t i o n a t the p o i n t where Ec e q u a l s E,,
and t h e a s s o c i a t e d g - f o r c e f o r a l l t h e couch s e c t i o n s a r e t a b u l a t e d
and a s i n g l e d e f l e c t i o n i s s e l e c t e d f o r t h e system which will. b e s t
s a t i s f y the o r i g i n a l design s p e c i f i c a t i o n s . By i n t e r p o l a t i o n a
new Nc ( c o r d s / i n z h ) f o r each s e c t i o n i s now determined and t h e

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DIVISION OF WALTER KlPDE & COMPANY. INC.
BURBANk, CALIFORNIA 91503
4.5 Procedure f o r Calculating Filament

Wound Enernv Absorbinn Cord D i r t t i b u t i s - C o n t .
energy absorbed i n t h e cords and g-loadingg a r e c o r r e c t e d by multi-
plying each by t h e r a t i o
N, ( i n t e r p o l a t e d ) . Based on
N, ( i n l t i a l l y approximated)
. -.
these c o r r e c t e d values, thh p o s i t i o n of energy balance and a n t i c i -
pated g-loading is again determined. These c o r r e c t e d Nc and g-load-
ing values a r e used t o f a b r i c a t e a.id a p p r a i s e t h e couch system.
The supporting configuration a s mentioned i n t h e s u m a r y above is
concerned with t h e v a r i a b l e r e s t r a i n t cord support angle 8 and cord
length 1, li o r lii a s they a r e r e l a t e d t o t h e v a r i a b l e d e f l e c t i o n ,
A *q, body shape and couch width dimensions. This i s shown by the
sketch be low.
4 C t-
MG
From the above
A *q it3 a r b i t r a r i l y s e l e c t e d and lii i s determined. wf is given

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D I V I S i O N OF WA!-TER KlDDE & COMPANY INC
4.5 Procedure f o r C a l c r ~ l a t i n gF'?Jam_egt

Wound Energy Absorbing Cord D i s t r i b u t i o n , Cant.
and wm and Dm a r e approximated t o a c h i e v e t h e b e s t match p o s s i b l e
w i t h t h e body shape - o v e r each s e c t i o n i n t o which i t i s d i v i d e d .
A l l a n g l e s are recorded i n r a d i a n s .
S o l v i n g f o r lii i n e q u a t i o n ( 4 )
Also
f = a-8
= s i n 1 5 or (
d
- i n 5) i f b i s n e g a t i v e
d
A f t e r s o l v i n g f o r lii over t h e s e r i e s of a . q ' s ( f o r each couch
s e c t i o n ) t h e percentage c o r d e l o n g a t i o n s a r e c a l c u l a t e d from t h e
formula
1 - 1
s t r a i n ( i n XI =
Applying t h i s v a l u e t o t h e s t r e s s - s t r a i n diagram f o r t h e r e s t r a i n t

WEBER AIRCRAFT
DIVISION O F WALTER K'DDE & COMPANY. INC.
4.5 Procedure f o r Calculating Filament Wound Energy

Absorbing Cord D i s t r i b u t i o n , Cant,
cord produces a cord s t r e s s , Sii, f o r each lii c a l c u l a t e d .
The g-loading f o r every increment of [lq can now be c a l c u l a t e d

by t h e r e l a t i o n s h i p s :
MG = 2 s i n O Sii
which can be transposed i n t o
2 s i n O Sii
G =
M
The support a n g l e 8 i s aimply + g2 o r by s u b s t i t u t i o n
B (sin
-'-
-1 e + sin-1 c )
a
The sample p r i n t out computer c a l c u l a t i o n , Table 14, i s f o r t h e
upper p e l v i c s e c t i o n of t h e couch with conditions a s s t a t e d .

Ml
i s t h e assigned mass/inch i n c l t , l i n g both body and a u i t weights and
M2 ( a constant) i s t h e i n e r t i a l reel p u l l .
F i n a l l y , t h e computer c a l c u l a t i o n s were r e f i n e d a s follows:
a, The d e f l e c t i o n a t zero cord stress f o r any i n i t i a l l y s t a t e d

condition i s automatically i n t e r p r e t e d and f e d i n t o t h e
c u l c u la t i o n .
b. The e f f e c t of t h e i n e r t i a l z e e l p u l l i s woven i n t o t h e
computer s o l u t i o n s .
c. A formula was developed f o r t h e stress curve by which t h e
v a r i a b l e stress Sii i a a u t a n e t i c a l l y fed i n t o t h e c a l c u l a t i o n s .

4.5 Procedure f o r Calculating Filament Wound Energy Absorbing Cord D i s t r i b u t i o n Cont.
-
TABLE 1 4
SAMPLE COMPUTER PRINT-OUT CALCULATION
Load L i m i t s 96541 17766

:=l W f Wb Wd hp MI M2 N, (approximated)
:=20.5 13.5 10.25 168.
:=2.05 (zero s t r e s s
noq)
7. Elong
0.00
0.63
1.33
2.11
2.95
3.87
4.86
5.91
7.04
8.22
9.47
10.78
12.15
18.17
24.93
32.28
40.09
48.26
56.69
65.33
74.12
83.04
92.05
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4.5
+-
Procedure f o r C a l c u l a t i n Filument Wound Energy
Absorbing Cord Distr u t on Cont.
d. The l a t e r a l r p r i n g i n t h e couch frame was r e l a t e d t o t h e
loading on t h e couch and can be f e d i n t o t h e c a l c u l a t i o n s .
Determination of t h e i n l i n e movement: of t h e couch frame was not
taken i n t o c o n s i d e r a t i o n i n t h e s e c a l c u l a t i o n s . This refinement
would have t h e e f f e c t of reducing t h e system d e f l e c t i o n noticeably
and t h e design cords/inch only s l i g h t l y .
h e secondary support l a c i n g i s c a l c u l a t e d i n t h e following manner:

The elongation a t break of t h e secondary l a c i n g and cwer i s
estimated.
This i s added t o t h e primary cord length e s t a b l i s h e d f o r a 1-g
loading. (The zero stress length of t h e secondary winding i s
made equal t o t h e 1-g loaded length of t h e primary winding and
thus does n o t a f f e c t t h e I-g Loaded d e f l e c t i o n of t h e l a t t e r . )
The maximum instantaneous load c a r r y i n g c a p a c i t y of t h e primary
cords a t t h e length e s t a b l i s h e d by Step 2 i s determined from
t h e computer c a l c u l . a t i m of t h e system.
The maxinnnu secondary breaking load t o l e r a b l e is e s t a b l i s h e d
by s u b t r a c t i n g t h e instantaneous primary c a p a b i l i t y f r a n 20-g.
REPORT NO. DR % ~ 3 PAGE 1°3

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & C O M P A N Y . INC
4.5 Procedure f o r C a l c u l a t L n g Filament

-
Wound Enernv Absorbing Cord D i s t r i b u t i o n - Cont.
The stress i n t h e primary c o r d f o r t h e l o a d e s t a b l i s h e d by
S t e p 3 is determined from t h e computer c a l c u l a t i c n s . (This
always t u r n e d o u t t o be g r e a t e r t h a n 607. of c o r d s i n h e r e n t
draw o r a t t e n u a t i n g s t r e s s . )
The load c a r r y i n g c a p a c i t y of t h e primary system a t breakout
of t h e secondary, assuming t h a t t h e c o r d ' s s t r e s s has decaved
t o 607. of i t s i n h e r e n t draw s t r c t 3, i s determined by m u l t i p l y i n g
t h e maximum l o a d c a r r y i n g c a p a c i t y ( S t e p 3) by t h e r a t i o (607.
c o r d draw s t r e s s $ s t r e s s from S t e p 5 ) .
The minimum b r e a k i n g load c a p a c i t y o f t h e secondary winding is
found by s u b t r a c t i c g t h e r e s u l t s of S t e p 6 from 16-g.
The maximum and minimum b r e a k i n g s t r e s s e s i n t h e secondary wind-
i n g r e l a t i n g t 1t h e maximum and minimum l o a d s ( S t e p s 4 and 7)
a r e determined by m u l t i p l y i n g t h e l a t t e r by t h e s i n e o f t h e
s u p p o r t a n g l e a s e s t a b l i s h e d by t h e computer c a l c u l a t i o n s .
(This i s t h e a n g l e e x i s t i n g a t t h e breakout of t h e secondary
l a c i n g a s summarized i n S t e p 2.)
The d e s i g n b r e a k i n g s t r e s s f o r t h e secondary l a c i n g i a t a k e n
a s t h e a v e r a g e of t h e v ~ q m i mand minimum c a l c u l a t e d by S t e p 8.
The grommet s p a c i n g f o r t h e secondary l a c i n g i s determined

WEBER AIRCRAFT
IURBANK, CALIFORNIA 91503
4.5 Procedure for Calculatin& Filament

Wound P;nernv Abrorbinn Cord D w b u t i o y - Cant.
frm the foraula:
where G, i r grorawt rpacing
Sd 'q the lacing derign 8Cre.s
Cb 1s the cord breaking strength and
a s shown by the rkctch:
REPORT NO. Pit-5893 PAGE 105

WEBER AIRCRAFT
4.6 R e s t r a i n t Harness Design
The r e s t r a i n t system is anchored t o t h e s p a c e c r a l t v i a i n e r t i a r e e l s
ow f o r t h e l e g s and two r e s t r a i n i n g t h e t o r s o . The t o r s o r e e l s a r e
p o s i t i o n e d such t h a t d u r i n g an e y e b a l l s - o u t f o r c e , a f o r c e p a r a l l e l
t o t h e o c c u p a n t ' s t o r s o i s c r e a t e d , t h e l a p b e l t i n t r o d u c i n g an up-
ward f o r c e , t h e s h o u l d e r b e l t g e n e r a t i n g a n e q u a l down force. By

l o c a t i n g t h e r e e l s i n t h i s manner, a degree of up and down s t a b i l i t y
i s i n t r o d u c e d d u r i n g t h e e y e b a l l s - o u t rebound.
To p r e v e n t t h e occupant from "submarining" under t h e l a p b e l t , a
webbing arrangement was d e v i s e d whereby t h s b e l t a c r o s s t h e l a p
p a s s e s through a seccxd webbing which goes around t h e i s c h i a l t u b e r -
o s i t i e s , sCrni1p.r t o a p a r a c h u t e h a r n e s s l i f t wet. The geometry o f
t h e arrangement p r e c l u d e s t h e n e c e s s i t y o f c r o t c h s t r a p s , r e q u i r i n g
o n l y a s i d g l e c o n v e n t i o n a l l a p b e l t "uckle t o be f a s t e n e d . The
s h o u l d e r s t r a p s a r e h e l d i n p o s i t i o n by t h e o c c u p a n t ' s s h o u l d e r and
buckle ~ n t ot h e l a p b e l t .
The r e s t z a i n t webbing is mechanically f a s t e n e d t o t h e body s u p p o r t by
screws p a s s i n g through grommets i n t h e body s u p p o r t . Fittings are
s e c u r e d t o t h e csrews oa t h e s i d e away from occupant and a r e connected
t o t h e i n e r t i a r e e l webbing by p a r a c h a t e r i s e r f i t t i n g s . Incorporated
i n t o t h e r e e l webbing a r e l e ~ i g t h so f b r a i d e d undrawn nylon c o r d s
v h i c h a t a 6 - g t o 10-g e y e b a l l s - n u t fo.ce draw, i i m i t i n g t h e f o r c e
r e c e i v e d by t h e occupant. The c o r d s a r e assembled a3 shown i n
F i g u r e 29.
REPORT NO. nR-5393 PAGE 106

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE 81 COMPANY. INC
4.8 Prototype Couch Frame Development T e s t i n g ( c o n t ' d )
The i n i t i a l s t a t i c t e s t s were h a l t e d due t o a s t r u c t u r a l f a i l u r e
i n the t o r s o platform s t r u c t u r e . Post-test analysis indicated t h a t
t h e body s u p p o r t t e n s i o n a n g l e was l e s s than t h a t used f o r t h e s t r e s s
a n a l y s i s of t h e couch frame. T h i s r e s u l t e d i n inward bending f o r c e s
on t h e couch frame t h r e e t o f o u r times g r e a t e r than a n t i c i p a t e d .
The t o r s o frame was s u b s e q u e n t l y r e d e s i g n e d t o accommodate t h e l a r g e r
f o r c e s and a new t o r s o s t r u c t u r e was f a b r i c a t e d .
The system was t h e n i n s t a l l e d on t h e s t a t i c t e s t f i x t u r e and a simu-
l a i d launch load was a p p l i e d t o t h e couch n e t and frame through a n
anthropomorphic dummy. The f o r c e s were a p p l i e d a t a c o n s t a n t r a t e
u n t i l t h e f r a n g i b l e c o r d s r u p t u r e d a t 13-g's. Data from t h e s t a t i c
iests i s summarized i n Table 15,
TABLE 15
STATIC TEST DATA - PROTOTYPE COUCH ASSENBLY
LOADING 1-n 8-R

--
13-n* I 1-n RETURN
I
Average D e f l e c t i o n 1.1 2.2 2.9 1.6
Allowable D e f l e c t i o n 1.5 - 3.0 1.5
* Rupture of f r a n g i b l e c o r d s .
The impact t e s t , s i m u l a t i n g ground l a n d i n g of t h e s p a c e c r a f t ,
y i e l d e d an average a t t e n u a t i o n f o r c e of 19.2-g's which is f a v o r a b l y
l e s s than t h e 20-g c b j e c t l v e . The high speed movies i n d i c a t e d a
uniform dummy d e f l e c t i o n w i t h no d i s c e r n i b l e r a c k i n g o r non-uniform
displacement of t h e dummy body members.
REPORT NO. DR-5893 PAGE llr,

WEBER AIRCRAFT
DIVISION O F WALTER KIDDE & C O M P A N Y . INC.
4.8 P r o t o t y p e Couch Frame D e v e l o ~ m n tT e s t i n q ( c o n t ' d )
The i n e r t i a r e e l lagged behind t h e i n i t i a l displacement o f t h e occu-
p a n t s a s a n t i c i p a t e d , b u t r e e l e d i n t h e s l a c k webbing b e f o r e t h e
dummy was a b l e t o rebound a measurable d i s t a n c e . The e y e b a l l s - o u t
rebound f o r c e s a r e w e l l below t h e maximum 10-g requirement. A sum-
mary of t h e dynamic t e s t d a t a i s shown i n Table 16,
During t h e v i b r a t i o n t e s t s , a n a t u r a l frequency of 10 cps was measured
a t t h e dummy's c h e s t d u r i n g t h e v i b r a t i o n t e s t s . A dampening e f f e c t
was recorded a t t h e head, p e l v i c and l e g a r e a s of t h e dummy through-
o u t t h e 0-60 cps frequency scan.

WEBER AIRCRAFT
4.8 Prototype Couch Frame Development T e s t i n g ( c o n t ' d )
TABLE 16
DYNAMIC TEST DATA
PROTOTYPE COUCH ASSEMBLY
1
PARAMETER EBI - EBO
Requirement
C a l i b r a t i o n Run
Test Results
I Dummy Response
Requirement 10-g (rnax

Test Results 5-g
(average)
Dummy D e f l e c t i o n
Requirement 10.5 i n s (max)
from 1-g
6.1 i n s (avg)
from 1-g
Requirement 30 FPS(max)
Calibration 28.8 FPS
Test Results 27.4 FPS
Permanent S e t
Inches (avg) 0.9 (Body 0.9 (Res-
supper t ) ' traint
Link)
k- I n e r t i a Reel Take':= 3.8 i n s (avg)
REPORT NO. DR-5893 -

WEBER AIRCRAFT
DlVlSlON OF WALTER KlDDE & COMPANY. INC.
4.9 NASA-MSC Supplemental T e s t s
( A s e r i e s of drop t e s t s were performed a t MSC f a c i l i t i e s t o augment
t h e dynamic t e s t s conducted a t Weber.
Two t e s t s were performed on t h e couch system, The f i r s t drop was
performed t o determine t h e low l e v e l c h a r a c t e r i s t i c s of t h e system.
The f o r c e s r e c e i v e d by t h e dummy were h i g h e r t h a n t h e i n p u t f o r c e of
9-g which i s a t y p i c a l response c h a r a c t e r i s t i c of a n e t o r f a b r i c
type couch system f o r low i n p u t f o r c e s .
The second drop t e s t e d t h e system a t t h e maximum a n t i c i p a t e d impact
conditions. This r e s u l t e d i n t o t a l s t r u c t u r a l c o l l a p s e of t h e
t o r s o frame s t r u c t u r e and f a i l u r e of t h e l a t c h mechanism which locks
the l e g platform i n its various positions. The a c c e l e r o m e t e r t r a c e s
f o r t h e s e t e s t s a r e shown i n F i g u r e s 31 and 32.
A f t e r review of t h e h i g h speed movies, i t was i n i t i a l l y concluded
t h a t d u r i n g t h e f r e e f a l l drop t h e n e a r zero-g f o r c e p e r m i t t e d t h e
dummy t o move o u t of p o s i t i o n by s e v e r a l inches. S i n c e t h e dynamic
t e s t s a t Weber demonstrated t h a t t h e body s u p p o r t does a t t e n u a t e
s l i g h t l y below a 20-g l e v e l , t h e high-g f o r c e s e x p e r i e n c e d by t h e
dummy's c h e s t and p e l v i s (from tile drop tower t e s t s ) s u g g e s t t h a t
t h e body s u p p o r t was " s h o r t c i r c u i t e d " o a t of t h e system, p e r m i t t i n g
t h e f u l l impact load t o be t r a n s m i t t e d t o t h e dummy through t h e
couch frame.
A Div151onof Walter Kidde 8 Cornpony, Inc.
Ourbank, California
4.9 NASA-MSC Supplemental Teets - Cont.

p-- 100 ,, 1-
SUPPLEPENTAL DROP TEST ACCELEROMETER DATA

32.8 PPS v ~ ~ o c xC nH A ~ G ~
WEBER AIRCRAF!' COMPANY
A D~visionof Walter Kidde 8, Cqmpany, In<.
WEBER AIRCRAFT
4.9 NAYA-MSC Supplemental T e s t s ( c o n t ' d)
The movies i n d i c a t e d t h a t t h e i n s t r u m e n t a t i o n l e a d s from t h e dummy
were t r a p p e d between t h e couch f r m e and upper arm of t h e dummy and,
a s t h e arm canle i n c o n t a c t w i t h t h e frame, t h e frame y i e l d e d and
f i n a l l y broke s y m n e t r i c a l l y , r i g h t a t t h e s h o u l d e r .
The f a c t that thc peak dummy f c r c e s were v e r y n e a r t h e des4.gn u l t i -
mate f o r c e of t h e couch frame seemed t o f u r t h e r s u b s t a n t i a t e l o c a l -
i z e d load p o i n t s i n s t e a d of a load d i s t r i b u t e d by t h e body su;,;mrt.
The high speed movies show t h e l e g s d e f l ~ r + I n gand s t r e t c h i n g t h e
f a b r i c a s desired. The movies a l s o i n d i c a t e d t h a t t h e l e g i n e r t i a
r e e l ;erfcrmed s a t i s f a c t o r i l y . ( A l l of t h e r e e l s f u n c t i o n e d p r o p e r l y
a f t e r the t e s t ).
F u r t h e r a n a l y s i s of t h e m w i e s ~ i i~n s pd e c t i o n of t h e couch frame
i n d i c a t e d t h a t t h e secondary f a i l u r e of t h e l e g p l a t f o r m l a t c h
mechanism o c c u r r e d when t h e t ~ c s oframe s t r u c k t h e angled b r a c z s on
t h e t e s t f i x t u r e and momentarily t a c k e d t h e lower u o r t i o n of t h e
frame such t h a t t h e p i v o t p i n s were wrenched o u t of t h e locked
latches. Bearing f a i l u r e c.f t l ~ el a t c h bores i n d i c a t e d no s l i d i n g
of t h e l a t c h which might r e l e a s e t h e p i v o t p i n .
Subsequently, s i x drop t e s t s were performed w i t h t h e body s u p p o r t s
i n s t a l l e d on an MSC f u r n i s h e d " b a i l e r p l a t e " couch frame. These
t e s t s i n d i c a t e d t h a t t h e high f o r c e s e x p e r i e n c e d by t h e d u m y may
n o t have been caused by t h e dummy r i d i n g on t h e couch frame d u r i n g
i m p ct .
PAGE 116
'WEBER AIRCRAFT
DlVlrjlON OF WALTER KIDDE & COMF'ANY. INC.
BURLANK CALIFORNIA 95 503
4.9 &IS-MSC Supplemental T e s t g ( c o n t ' d )
During t h c t e s t s non-uniform diepl.accment and h~.gh f o r c e s were r e -
c e i v e d by t h e dummy. Small displacement and h i g h a c c : : l e r a t i o n f o r c e s
were noted p r i m a r i l y i n t h e s h o u l d e r a r e a of t h e dunrmy. The l e g
s e c t i o n of t r e body s u p p o r t , however, f u n c t i o n e d a s designed. The
r e s u l t s of t h e s e t e s t s a r e summarized i n T a b l e s 17 and 18. The a c -
c e l e r o m e t e r d a t a i s p r e s e n t e d i-, F i g u r e s 33 through 38.
A review of t h e body s u p p u r t d e s i g n was coaducted t o determine i f
t h e cause of t h e e r r a t i c performance c o u l d be i s o i a t e d . nognizant
MSC, Weber end bodv s u p p o r t isupplier r e p r e s e n t a t i v e s were p r e s e n t .
A r e v l e v and dl 3cussian o f t h e e q u a t i o n s a n J computer a n a l y s i s
t e c h n i q u e used by t h e body s u p p o r t s u p p l i e r t o c a l c u l a t e t h e c o r d
d i s t r i b u t i o n and a t t e n u a t i n g l e v 2 1 of t h e system w~,a conducted.
There d i d n o t appear t o be any obvious a r e a s i n t h e i r approa=h which
c o u l d cause t h e u n p r e d i c t e d r e s u l t s a t t a i n e d d u r i n g t h e d r c p tower
t c s ts.
REPOR? NO. DR-5893 PMGE 117

WEBER AIRCRAFT
PAGE 118
REPORT NO. Dq-5893
WEBER A l R C R A n COMPANY
A Div~sionof Walter Kidde b Compuny, I n c .
Burbank, California
--
----I
-- INPUT
CHEST
SIRPUIIEIITAL DROP TEST DATA

)ODT SUPPdBT ASSEMBLY
33.0 ??S VELOCITY C W t
PAGE 120
REPORT NO. -3
A Division of Walter Kidde 6 Company, Inc.
Burbonk, California
- Cont.
- -i
W l n S C Supplamntal Tertr
-t loo
-
REPORT NO. R 5893
A Division of Wolter Kidde & Company, Inc.
Burbank, California
.--.-.-- ----....-. ------
I------
4.9 NASA-MSC Supplemental Tests - Cont.
- INPUT
- - CHeST
- - - HEAD
SUPPLEHENT& DRO? nsl DATA

BODY SUFPORT A S S m L x .
3 5 3 ns nLmm-r
A Division of Walter Kidde B Company, Inc.
Burbonk, California
---..-- - 1
4.9 NASA-MSC
--
Supplemental
Tests Cont,
CHEST
,HEAD
--
REPORT NO. I
S 589? PAGE 123
WEIIER A l R C R A n COMPANY
A Divis~onof Wolter Kidde 8 Company, Inc
Iburbank, California
4.9 -
NASA-MSC
--
33 5 (EST. )
--
.
Supplemental T e s t s
Con t
.8
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CHEST
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SUPPORT ASSEMBLY - 32.0 IPS VELOCITY
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REPORT NO. 5893 PACE 124
WEBER A l R C R N T COMPANY
A Division of Walter Kidde & Company, Inc.
Burbank, California
--
- P P W T A L DROP PEST DATA

S U---
BODY SUPPORT A SS w Lf - 33.0 n'V ' E - ~ ~ - C R A W C--------
---We
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REPORT NO. --. PAGE 125

WEBER AIRCRAFT
SURBANK, CALIFORNIA 91 5C3
4.9 NASA-MSC S ~ ~ p p l e m e n t aTests

l ( c o n t ' d)
A general discussion r e l a t i n g t o a11 known v a r i a b l e s was held and
the possible e f f e c t of these v a r i a b l e s on the dynamic performance
of t h e system was estimated with t h e following r e s u l t s :
Estimeted PoseibLe E f f e c t
Possible Causes on Attenuation Level
Weight d i f f e r e n c e s i n dummy from spec.
Weight d i f f e r e n c e s of equipment from

spec. (pressure s u i t , helmet, boots,
etc)
Dummy p o s i t i o n
Ambient conditions
(Temp., e t c , )
Covch frame d e f l e c t ion
Fiber Unknowns
Dummy Cross-sectional shape, change

from Assumed Configuration
The sum of the possible v a r i a b l e s could i n c r e a s e the a t t e n u a t i n g
l e v e l by 17-g's. This r e f l e c t s a maximum accumulation of t h e worst
possible conditions. An increase of 30-g's however, was recorded
during t h e MSC drop tower t e s t s where a l e v e l of 20-g's was
desired, but a 50-g l e v e l was a t t a i n e d i n t h e shoulder a r e a .
The only remaining major cause t h a t could be seen was a f r i c t i o n
force c r e a t e d by t h e cover f l a p . This f l a p is provic on t h e body
support t o p r o t e c t t h e f r a n g i b l e lacing cords. It overlaps t h e
centerpiece of t h e body support cover and i s sewn t o the o u t e r por-
t i o n which i s a t t a c h e d t o t h e couch frame. When t h e dummy i s
-
WEBER AIRCRAFT
DIVISION OF WALTER KlDDE 8. COMPANY. INC
' BURBANK, CALIFORNIA 91 503
4.9 NASA-MCC S u ~ p l e m c n t a lT e s t s ( e o n t ' d)
p o s i t i o n e d on t h e couch, i t s s h o u l d e r s beat d i r e c t l y on t h e f l a p ,
p r e s s i n g i t or.to t h e c e n t e r p o r t i o n of t h e body s u p p o r t cover. It.
i s t h e o r i z e d t h a t during t h e i n i t i a l inpedt f o r c e , t h e cover f l a p i s
"pinched" between +he s h o u l d e r s of t h e dummy and t h e body support
cover, r e l i e v i n g t h e f r a n g i b l e cords and t h e a t t e n u a t i n g cords of
a s u b s t a n t i a l amount of f o r c e .
A f r i c t i o n t e s t , u s i n g m a t e r i a l s s i m i l a r t o those used i n t h e sup-
p o r t system was performed. The m a t e r i a l s were assembled and
s t a t i c a l l y 'oaded such t h a t i t simulated t h e loading c o n d i t i o n of
t h e cover f l a p trapped between t h e body support cove? l a y e r and t h e
s u i t e d dummy. It was found t h a t t h e f o r c e r e q u i r e d t o move t h e
c e n t e r l a y e r of m a t e r i a l simul.ating t h e cover f l a p s l i g h t l y exceeded
the applied force. This t e s t appears t o s u b s t a n t i a t e t h e a n a l y s i s
whict i n d i c a t e d t h e major s i n g l e f a c t o r i n c r e a s i n g t h e system
a t t e n u a t i o n l e v e l is t h e f r i c t i o n cnuaed by tlrc cover f l a p .
Analysis of t h e supplemental t e s t s concluded t h e Phase I e f f o r t
of t h e program and served a s t h e b a s i s f o r determining t h e modifica-
t i o n s and a d d i t i o n a l t e s t s r o be accomplished during Phase XI.

WEBER AIRCRAFT
5 .O PHASE I1 - FABRICATION AND TEST

A l l work accomplished d u r i n g Phase I of t h e program was approved
and t h e d e t a i l e d Phase 11 d e s i g n m o d i f i c a t i o n task, a s provided
i n t h e c o n t r a c t was outlined.
Phase I1 of t h e program was provided t o i n c o r p o r a t e m o d i f i c a t i o n s
t o t h e couch frame and body support r e s u l t i n g from t h e Phase I
tests, t o perform a d d i t i o n a l t e s t s a s may be r e q u i r e d and t o
~ e s i g nand f a b r i c a t e a three-man couch system capable of being
i n s t a l l e d i n t h e Apollo Cournand Module.
A s u f f i c i e n t q u a n t i t y of body supports and r e s t r a i n t assemblies
t o pennit e v a l u a t i o u of t h e t h r e e couch system by MSC were provided.
5.1 -
Three C ~ u c hSystem
Authorization t o proceed with t h e design and f a b r i c a t i o n
of t h e couch suspeneior. s t r u c t u r e c o n c u r r e n t l y with t h e
f a b r i c a t i o n and t e ~ t i n gof the prototype couch assembly
was received.
The s t r u c t u r e a s designed and c o n s t r u c t e d c o n s i s t s of
r i g i d s t r u t s t o p o s i t i o n t h e t h r e e couches i n t h e C m a n d
Module. Four X-X s t r u t s a t t a c h t o two couch $$port beams
which a r e p o s i t i o n e d i n t h e plane of t h e Z-Z and Y-Y axes.

WEBER AIRCRAFT
5.1 Three Couch Svstem - Cont.

The l a r g e a t of t h e two beams is ,located below t h e b u t t o c k s
. ~ ft h e crew r&mCei and s u p p o r t s most of t h e s p a c e c r a f t

I
launch and 1andir.g l o a d s ; t h e balance of t h e l g a d i s s u s t a i n e d
by t h e upper beam. The b u t t o c k , o r t a i l beam, i s a
continuous s t r u c t u r e which, i n a d d i t i o n t o c o n t a i n i n g t v o
attachment p o i n t s and l a t c h i n g m c h a n i s m f o r each couch,
a l s o p r o v i d e s a t r a c k which g u i d e s t h e l e f t couch i n t o t h e
docking p o s i t i o n . Large p a d s on e i t h e r end o f t h e beam

I
t r a n s m i t compression l o a d s i n t o t h e Y-Y b e a r i n g p l a t e s of
t h e Apollo Comnand Module. A second beam i s l o c a t e d above
t h e heads of t h e crew members. The s i n g l e upper a t t a c h
p o i n t of each couch and t h e second p a i r of X-X s t r u t s a r e
pinned t o t h i s beam. The t a i l and head beams a r e i n t e r -
connected by a l i g h t s t a b i l i z i n g beam t o which 2-2 s t r u t s
a r e attached. The suspension s t r u c t u r e is shown i n F i g u r e 39.
Figure 40 shows t h e completed Apollo t h r e e man couch system.
The weight o f t h e t h r e e man u n i - d i r e c t i o n a l n e t t i n g t y p e
couch system, u t i l i z i n g a c t u a l component weight is as
follows:

WEBER AIRCRAFT
5.1 Three Couch System - Cont.

Assembly Weber Drawinn
Couch S t r u c t u r e Assy 23.5 SK-10343 (Basic)

Body Support Assy 9.0 SK-10344-401
I n e r t i a Reel &
Controls I n s t l . 4.1 SK-10365 (Basic)
Total Couch Assembly 36.6 l b s .
Three Couch Assemblies 109.8

Suspension S t r u c t . Assy 55.0 SK-10342-201
S/C C o n t r o l l e r F i t t i n g s .4 SK-10376 (Basic)
Total System Weight 165.2 l b s .
5.2 Phase I1 Couch Modification and T e s t s
P r i o r t o f a b r i c a t i n g t h e balance of t h e hardware and s o f t -
ware i t m e a d d i t i o n a l t e s t i n g were performed a t MSC t o
s u b s t a n t i a t e t h e s t r u c t u r a l adequacy of t h e couch frame
and t h e attenuat,on p r o p e r t i e s of t h e body support during
t h e maximum impact conditions.
Only minimum design changes t o a s s u r e s t r u c t u r a l i n t e g r i t y
of the couch s t r u c t u r e were made. A s a r e s u l t of the
previous couch frame c o l l a p s e t h e t o r s o frame s t r u c t u r e
was strengthened, primarily by e l i m i n a t i n g a s t r u c t u r a l
s p l i c e i n t h e beam s e c t i o n a t t h e shoulder area.

WEBER AIRCRAFT
5.2 Phase 11 Couch Modification and T e s t s - Cont.

Three body support assemblies were f a b r i c a t e d , salvaging
usable cmponents from previously t e a t e d assemblies.
Two body supports were f a b r i c a t e d i n t h e sme c o n f i g t r a t i o n

as previously t e s t e d except e x t r a a t t e n u a t i n g cords were
provided. The f i n a l cord d i s t r i b u t i o n was t o be determined
a f t e r a s e r i e s of draw f o r c e tests were performed a t t h e
Systems Test Branch. A t h i r d support of a s l i g h t l y
d i f f e r e n t c o n s t r u c t i o n was a l s o provided by t h e s u p p l i e r ,
5.3 Additional Prototype Souch Testing
To determine t h e number of required a t t e n u a t i n g cords,
samples were taken from t h e t e s t specimen and t e s t e d on an
I n s t r o n a t t h e Systems Test Branch f a c i l i t y j u s t p r i o r t o
each t e s t . . These r e s u l t s were compared t o the draw f o r c e
of cords brought by body support s u p p l i e r d i r e c t l y from
h i s lzboratory. I n a l l cord samples, draw s t a r t e d a t 1.6
t o 1.7 pounds. It was then decided t o take s e v e r a l samples
and s u b j e c t them t o d i f f e r e n t environments f o r 24 hours
t o determine what e f f e c t i t may have on draw force. Samples
were subjected t o vacuum a t r o m temperature, 1 6 0 ' ~ a t
roam atmosphere, and standard l a b o r a t o r y environmental
c o n d i t i o n s of 70' - 7 2 ' ~ a t 41% t o 46% r e l a t i v e humidity.

WEBER AIRCRAFT
5,3 Additional Prototype Couch T e s t i n g - Cont.

The r e s u l t s of t h e s e t e s t s appear t a suggest t h a t t h e
moisture content contained i n t h e f i b e r s a s being t h e
f a c t o r having t h e g r e a t e s t s i n g l e e f f e c t on t h e draw f o r c e
level. h e r e s u l t s of t h e s e t e s t s a r e tabulated i n
Table 19.
Based on t h e cord draw f o r c e t e s t r e s u l t s , t h e cord d i s t r i -
bution f o r t h e f i r s t drop was calculatec2 on a 1.8 draw force
per cord. Review of t h e elonpation requirements f o r t h e
v a r i o u s cords i n t h e body support a t maximum d e f l e c t i o n
i n d i c a t e d t h a t f o r most of t h e arpport, 80% t o 120%
elongation i s required. I n t h e shoulder area, however,
elongation on t h e order of 160% t o 200% i s required due
t o r e s t r i c t e d e f f e c t i v e cord length.
Since t h e supplementary body support tests i n d i c a t e d t h i a
a r e a of support might be too strong, and t h e j u s t performed
draw tests i n d i c a t e d an i n c r e a s e of draw f o r c e t o 2.2. lbs.
a t 200X elongation, i t was decided t o campensate f o r t h i s
i n c r e a s e i n t h e shoulder-upper a m area.
Additionally, previous l a b o r a t o r y tests i n d i c a t e d t h a t when
s e v e r a l cords a r e drawn over a h a r d edge, such a s t h e

ATTENUATING CORD D R A W FOhCE TESTS
DRAN FORCE AND

CORD SAMPLE T, ELONGATION AT START DRAW FORCE CRAW FORCE
OF DRAW @ 100% ELONGATION @ZOO% ELONGATION
Test Results at 2.3 Ib. t o

S u p p l i e r ' s Laboratory 2.9 l b .
72O 50% R.H.
F r a u Couch a t MSC
f o r 4 days 1.5 lb.
*
F r a n S u p p l i e r 's 1.8 l b . @
Spool, U n c o n t r o l l e d 2091 1.: lb. 2.2 l b .
Envirorrmen t
-~ -
F r a n Spool a f t e r
24 Hr @ 7 0 9 , 1.8 l b . @
42Z t o 46% R.H. 20% 1.8 l b . 2.3 l b .
2 4 h r . soak i n
Vacum @ 70°p
24 h r . soak i n 2.2 l b . @
w e n a t 170' ?; 10% 15% 2.2 l b . 2.2 Ib.
NOTE: A l l cords b r o k e between 5.5 t o 6.5 l b s . f o r c e @ 400% t o 600% e l o n g a t i o n .

WEBER AIRCRAFT
DlV'SlON OF WALTER KlDDE & COMPANY. INC.
5 .3 Additional Prototype Couch T e s t i n g - Cont,

i n s i d e corner of t h e couch frame, t h e draw f o r c e i n c r e a s e s
15% t o 202, This f a c t o r was a l s o taken i n t o account i n
determining t h e f i n a l number of cords t o be used i n t h e
body support.
With t h e s e f a c t o r s taken i n t o consideration, t h e f i n a l cord
d i s t r i b u t i o n i n t h e shoulder a r e a was based on a 2.4
pound draw force, t h e remainder of t h e body support
predicated on a 2.15 pound draw force.
For t h e f i r s t t e s t body support, SIN 005, was i n s t a l l e d
on the MSC " b o i l e r p l a t e " couch, i t s secondary cover f l a p s
taped back out from under t h e dummy and t e s t e d with a
Weber furnished dunmy, which was b a l l a s t e d t o t h e s p e c i f i c a -
t i o n weight d i s t r i b u t i o n .
The accelerometer d a t a and p o s t - t e s t d e f l e c t i o n d a t a from
t h i s t e s t i s presented i n Table 20 a s Drop number 1. The
r e s u l t s i n d i c a t e good a t t e n u a t i o n l e v e l s , somewhat below
the 20-g requ hements and a l a r g e amount of n e a r l y uniform

permanent set ( p l a s t i c deformation) i n t h e a t t e n u a t i n g
cords. However, l a r g e s p i k e g-forces were recorded by t h e
dummy accelerometers. This was d.. termir.ed t o be unacceptable.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPAhrY. INC
5.3 -Additional Prototype Couch T e s t i n g - Cont,

-- 20
TABLE
PROTOTYPE COUCH DROP TESTS
DROP 1 DROP 2 DROP 3
Velocity Change
(FPS) 31.4 32.0 32 .O
Input Force (g) 41 .O 44 ,. 1 44.0
Dwmy Response Head 17.4 19.2 18.5

( g)
Chest 18.O 16 .O 18 .O
Lei? 19.7 19.2 20.0
Dunany Displacement Head

(post t e s t - r e e l s Chest
locked)
Pelvic
Inches I.
Legs
-
Dynamic Displacement Head

of D m y Chest
Inches Pelvic
Legs
-
Permanent Displace- Head 5.94 9.87 9.38

ment due t o s t r e t c h Chest 5.25 8.62 8.50
of body support Pelvic 4.25 7.75 7.88
Legs 2 .OO 5.00 5.75
I n e r t i a Reel Shoulder 6.50 9.25 9.88

Take Up Lap 6.25 8.62 8.63
Incher Leg 5 .OO 6.25 6.25
REPORT NO. -DR 5893 PAGE 137

WEBER AIRCRAFT
DIVISION O F WALTER KlDOE & COMPANY. INC.
5.3 Additional P r o t a m e Couch Te- - Cont.
It war aubaequently decided t o u t i l i z e an experimental
body rupport, derigned and fabricated by the body support
r u p p l i e r t o conduct an additional t a r t with the ryatem
i n r t a l l e d on t h e b o i l e r p l a t e couch. The cord d i s t r i b u t i o n
of t h i r rupport, SIN 007, war the rome a r t h e previour t e a t
except i n t h e rhouldsr a r e a where, due t o the special cord
araembly, the draw force war bared on the rama 2.15 pound
draw a8 t h e remainder of t h e platform.
The secondary support lacing, which provider the 16-g
r t a t i c load c a p a b i l i t y of the body rupport, war removed t o
ree i f i t war t h e caure of the rhrrp a c c e l e r a t i o n forces
recorded on the f i r r t drop. The procactive cover f l a p s
were a l r o held back ro they would not influence the
attenuation of the dunmy. An additional accelerometer war
added t o the b o i l e r p l a t e couch frrrm i n t h e rhoulder area
t o d a t e m i n e i f there war any s i g n i f i c a n t amplification o r
attenuation of the input force by the frrms. The r e r u l t r
of t h i s t a r t , Drop Teat 2 r h m i n Table 20, i n d i c a t e the
e l i P i n r t i o n of t h e l a r g e rpike force noted i n t h e f irrt
drop with r k i l a r attenuation l r v e l r and a r i g a i f i c a n t
increau i n d w ddl#placemnt.

WEBER AIRCRAFT
DIVIS13N OF WALTER KlDDE & COMPANY. INC.
Additional Prototype Couch T e s t i n g - Cont.

The body support used f o r t h i s test employed a diagonal
cord winding i n t h e shoulder a r e a t o e f f e c t a longer UP-
r e s t r i c t e d cord length, reducing t h e required percentage
of cord elongation from 1607. t o 200% down t o 802 t o 120%
elongation, s i m i l a r t o t h e rest of t h e body support
a t t e n u a t i n g cords. This, i t was believed, might provide
a mote uniform a t t e n u a t i o n l e v e l i n t h e shoulder araa.

I
The c o n f i g u r a t i o n r e s u l t e d from t h e f a c t t h a t t h e e f f e c t i v e
cord length i n t h e shoulder a r e a with t h e s t r a i g h t winding
c o n s t r u c t i o n of t h e standard support assembly r e s u l t s i n
r e s t r i c t e d e f f e c t i v e cord iength due t o t h e width of t h e
s h o t i d e r s and i t was believed, might p a r t i a l l y c o n t r i b u t e
t o t h e low displacement and high g-forces recorded i n t1.e
shoulder a r e a during t h e body support e v a l u a t i o n tests
performed e a r l i e r . It b B evident from t h i s second drop
test t h a t t h i s type of constru,tion does improve t h e
a t t e n u a t i o n c h a r a c t e r i s t i c s , but allowance for t h e change
i n draw f o r c e due t o t h e higher percentage of elongation
does a l s o . Allowance f o r higher draw f o r c e r e s u l t s i n a
simpler c o n s t r u c t i o n method and i s much e a s i e r t o f a b r i c a t e .

WEBER AIRCRAFT
5.3 Additional Prototype Couch T e s t i n q - Cont.
The t h i r d drop was performed w i t h t h e Weber couch frame,
SK 10343-403 S I N 001, body support SK 10344-401 SIN006,

and t h e Weber dummy. The cord d i s t r i b u t i o n of t h e f i r s t
drop was used, t h e p r o t e c t i v e f l a p s were p o s i t i o n e d c l e a r
of t h e durrmy and t h e secondary l a c i n g c o r d s were removed.
The r e s u l t s of t h i s t e s t , s i m i l a r t o t h o s e of Drop 2, were
considered e x c e l l e n t . The d a t a shown a s Drop 3 i n Table 20
i n d i c a t e s t h i s t e s t r e s u l t e d i n t h e b e s t d u m j response
of t h e t h r e e t e s t s performed.
The accelerometer races f o r t h i s s e r i e s of t e s t s a r e

shown on Figures 41, 42 and 43. Figure 44 shows t h e dum-
my i n t h e a t t e n u a t e d p o s i t i o n a f t e r Drop t e s t 3 .
I n a l l t e s t s i t was noted t h a t a small peak i s recorded
on t h e dunmry accelerometers a f t e r decay of t h e input
acceleration. This peak, most: n o t i c e a b l e i n t h e dunrmv
c h e s t accelerometer, i s of i n t e r e s t .
The method of r i g g i n g t h e dumny may produce t h i s e f f e c t
s i n c e t h e knees of t h e dummy were t i e d t o i t s upper arms
t o c o n t r o l t h e l e g angle during t h e f r e e f a l l phase of t h e
drop. During t h e impact phase, t h e l e g s map have t r i e d t o
l i f t Lhe dunmy's shoulders. This was not n o t i c e a b l e i n
t h e high speed photography.
REPORT NO. DH 5893 PAGE

WEBER AIRCRAFT
5.3 -
Additional Prototype Couch Testing - Cont.
28 g ( l e g peak)
- 31.7 g (chest peak)
Attenuatiqn Level
I
31.8 g Head Peak
!IEG
CHEST
HEAD
I
-FIGURE
---- 41
PROTOTYPE TESTS - "Q02--1
MSC BOILERPLATE COUCH
WITH- SECONDARY_-LAC*
A IhiUT a t
Couch Stud

WEBER AIRCRAFT
BURSANK, CALIFORNIA 91503
5.3 Additional Prototype Couch Testing - Cont.
Attenuation
1 - CHEST
F_IBE31
PROTOTYPE TEST - DROP 2,
MSC BOILERPLATE COUCK- 1 Frame a t
-
SECONDARY LAC1 NG R@OoFvED
Couch Stud

WEBLR AIRCRAFT
DIVISION C'F WALTER KlDDE & C O H P A N Y . INC
BURUANK, CALIFORNIA 9 i' 503
5.3 -
Additional P r o t o r y ~
Couch Testing -
COP^.
1
I
1 -
LEG
I
1
1
I
I
I
I
1
I
I
1
1 CHEST
FIGURE 43
-
PROTOTYPE TEST DROP 3
WEBER COUCH -
S E C O ~ J ~ ~ ~
LACING REMOVED

WEBER AIRCRAFT
DIVISION O F W A L T E R KlDDE & C O M P A N Y . INC.
5.3 Additional Prototype Couch Testing - Cont.

It i s believed t h a t t h i s peak i s rilore l i k e l y caused by
t h e r e l e a s e of e l a s t i c energy s t o r e d i n the couch frame-
work due t o frame d a f l e c t i o n s during t h e i n p u t p u l s e of
t h e impact force. Disregarding t h e high peaks recorded
by t h e dummy during t h e f i r s t drop, t h e r e a r e t h r e e lower
magnitude peakslplateaus recorded by a l l dummy accelerometers
f o r each drop. 'Ehese occur a t n e a r l y c o n s t a n t i n t e r v a l s of
10 t o 15 milliseconds.
When compcred t o t h e r e l a t i v e r i g i d i t y of each s e c t i o n of
t h e couch framework, a c o r r e l a t i o n of r i g i d i t y and smooth-
ness of t h e dunmy's response can be seen. Large undulating
excursions of t h e l e g accelerometer with t h e r e l a t i v e l y non-
r i g i d l e g platform s t r u c t u r e , a sharp, i n i t i a l s p i k e and
small excursions of t h e more r i g i d t o r s o platform s t r u c t u r e .
The head frame s t r u c t u r e i s s u b j e c t t o less inward d e f l e c t -

i o n s than t h e rest o f t h e s t r u c t u r e , b u t due t o t h e s t r u c t -
u r a l change i n d i r e c t i o n i s s u b j e c t t o l a r g e r t o r s i o n a l
d e f l e c t i o n s which could e f f e c t t h e smoother a t t e n u a t i n g
response. Only a d d i t i o n a l t e s t i n g could s u b s t a n t i a t e t h i s
theory of e l a s t i c response.

WEBER AIRCRAFT
5 .3 Additional Prototype Couch Testing - Cont.

The conclueion of t h i s test series e s t a b l i s h e d t h e
following f a c t s :
The primary, a t t e n u a t i n g cord system of t h e body
support i s functioning a s designed.
The secondary c w e r p r o t e c t i v e f l a p was t h e cause of
t h e u n p r e d i c t a b l e and non-uniform d m y response
experienced during t h e two previous test s e r i e s a t
MSC .
The f r a n g i b l e cord of t h e secondary support system
produces unacceptably high, though temporary, g-forces
on t h e dummy.
The temperature-age h i s t o r y of t h e a t t e n u a t i n g m a t e r i a l
has a n e g l i g i b l e e f f e c t on i t s a t t e n u a t i n g p r o p e r t i e s .
Changes i n moisture content, however, r e s u l t i n
s i g n i f i c a n t changes.
The prototype couch frame, designed and f a b r i c a t e d by
Weber, i s s a t i s f a c t o r y when t h e body support f u n c t i o n s
properly .
Item (B) i n conjunction with Item (C) was t h e probable
cause of t h e s t r u c t u r a l f a i l u r e of t h e couch frame
d u r i n g t h e f i r s t test series a t MSC.

WEBER AIRCRAFT
D I V I S I O N OF WALTER KlDDE & C O M P A N Y . INC.
5.3 A M - Cont .
Based on t h e e v a l u a t i o n of t h e prototype couch a t MSC,
Weber was d i r e c t e d t o incorporate tile following changes
the body support:
Eliminate t h e p r o t e c t i v e c w e r f l a p of t h e secondary
suppor t system.
Determine a method t o e f f e c t smooth t r a n s i t i o n of
impact f o r c e s from t h e secondary support t o t h e primary
support systen: without reducing t h e s t a t i c load bearing
c a p a b i l i t y of t h e body support,
Provide method t o a d j u s t t h e length of each l a p b e l t
half,
Reduce t h e h e i g h t of t h e h e a d r e s t s t i f f e n i n g web i n t h e
a r e a of t h e occupant's neck and trim t h e l e n g t h of t h e
headrest s o i t w i l l n o t impair t h e comfort of t h e occupant
The couch s t r u c t u r e was found s a t i s f a c t o r y a s d e l i v e r e d

for teat.

WEBER AIRCRAFT
5.4 Body Support Section T e s t s
Additional body support tests were l a i d out t o i n v e s t i g a t e
t h e p o s s i b i l i t i e s of e l i m i n a t i n g t h e a t t e n u a t i o n s p i k e
curve i n f u r t h e r platfonn designs. A 12 inch specimen,
r e p r e s e n t i n g a t y p i c a l body t o r s o s e c t i o n was s e l e c t e d f o r
t h e t e s t program which c o n s i s t e d of both low speed load
a p p l i c a t i o n and high speed impact (drop) t e s t s .
An 88.5 pound drop weight with a p r o f i l e simuLating t h e
lower t o r s o of t h e occupant was used. The test specimens
c o n s i s t e d of a primary a t t e n u a t i n g support and superimposed,
v a r i o u s secondary l a c i n g supports. Lacing cords used a r e
described i n Table 21.
The primary a t t e n u a t i n g cords c a l c u l a t e d f o r t h e weight
and c r o s s s e c t i o n of t h e simulating t o r s o s e c t i o n r e s u l t e d
in:
5 1 ends/inch based on a draw s t r e s s of 1.5#
36 ends/inch based on a draw s t r e s s of 2.18
32 ends/inch based on a draw stress of 2.M
T h i r t y - s i x cords per inch were used for two drop t e s t s .
Thirty-two however, more n e a r l y produced t h e a t t e n u a t i n g
c h a r a c t e r i s t i c s d e s i r e d and were used f o r t h e remainder of
t h e tests conducted.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & COMPANY. I N C
BURBANK, CALIFORNIA Y 1503
REPORT NO. PAGE 149

WEBER AIRCRAFT
5.4 Body Support Section Tents - - Cont.

C a l c u l a t i o n s of t h e secondary lacing, predicated on using
a double l a y up of Specimen 4 above and an e f f e c t i v e
breaking s t r e n g t h of 18 lba. ( i n accordance with t h e
p r a c t i c e followed p r i o r t o t h i s t e s t s e r i e s ) e s t a b l i s h e d
a granmet spacing of .857". Thia f a c i l i t a t e s 28 s i n g l e
cord crossovers i n a 12" s e c t i o n o r 56 assuming t h e doubled
lacing. The design s t r e n g t h of 18 lbs. is only 61% of t h e
cords' normal t e n s i l e s t r e n g t h .
Because tests suggested t h a t t h e elongation at break of a
l a c i n g o r t h e secondary support s t r u c t u r e is g r e a t e r than
o r i g i n a l l y a n t i c i p a t e d , a revised i n p u t became a v a i l a b l e
and new c a l c u l a t i o n e of t h e secondary l a c i n g f o r t h e test
s e c t i o n were made. These d i s c l o s e d t h a t a l a c i n g only 82%
a s s t r o n g a s o r i g i n a l l y c a l c u l a t e d w i l l b e s t s a t i s f y the
design s p e c i f i c a t i o n s .
R e s u l t s of t h e drop tests conc?ucted a r e eumnarizea i n
Table 22. A gronnnet spacing e s t a b l i s h e d by t h e f i r s t
described c a l c u l a t i o n s was incorporated i n t o t h e sanples
tested. The i n p u t parameters were 30-32 f p s v e l o c i t y ,
40.45- g ' 8.
REPORT NO. JNl 5893 - PAGE 150

5.4 Bodv S u ~ m r tS e c t i o n T e a t s - Cont.
.. .
BODY- SUPPORT SECTION
- DROP TESTS
Percentapre of
Drop NO. of No. of ~heoret ~nitial Revised Recorded -R ' s
Test Primary Lacing Cord Lacing Lacing Calculated Calculated
No.
- Cords Material
-- Cross-overs Strennth R e ~ u i r e m e n t _Requirement Input Spike Plateau
None (Cont r o l l ' 43 16
Dacron Type 68 40 25 3
V i n a l PVA
Dacron Type 68
H. Ten. Rayon,
Nylon Type 6 4
Dacron Type ~2~ 3
Dacron Type
Low Ten. Rayon
Dacron Type 5 26
None ( C o n t r o l )
Dacron Type 5 2
Dacron Type 5 2
Nylon Type 714
A s s u m e s 617, s t r e n g t h e f f i c i e n c y i n l a c e d c o n f i g u r a t i o n .
Data q u e s t i o n a b l e .
Delayed s;?ike.
High t e n a c i t y .
Estane coated.
Undrawn nylon h r a i d e d c o v e r .
Rubber l i n e d grommets
WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & COMPANY. INC.
5 .4 Body Support Section T e s t s - Cont.

For each test made, t h e drop weight w a s f i r s t placed on
the primary windings. Under t h e 1-g loading, t h e
secondary l a c i n g s were snugged up and fastened. High
speed load t r a c i n g s of s e v e r a l drops a r e shown i n Figure 45
through Figure 48.
Next - pull t e s t s were made on a fuil s c a l e , 12" wide,
secondary support s e c t i o n which d u p l i c a t e d t h e corresponding
elements of t h e drop t e s t samples. The r e s u l t s of t h e s e

a r e summarized i n Table 23.
It is apparent t h a t t h e s i n g l e saw-tooth l a c i n g i s s u p e r i o r
t o the other lacing configurations. C o n s i d e x n g t h i s type
only, a 61% l a c i n g e f f i c i e n c y a s was previously assumed
does n o t appear t o be o u t of l i n e .

WEBER AIRCRAFT
1 5.4 Body Support Section Teats - Cont.

WEBER AIRCRAFT
5.4 Eody Support S e c t i o n T e s t s - Cont.
BODY SUPPORT SECTION DROP TEST 8

(FINAL DESIGN CO?@IGURATION DACRON 52 LACING1

WEBER AIRCRAFT
DIVISION O F W A L T E R K I D D E & C O M P A N Y . I N C .
5.4 Body Support Section T e r t r - Cont.
*.
FIGURE 47
BODY SUPPORT SECTlON DROP TEST -11
(PRIMARY CORDS aNLY)
REPORT NO. Da 5893 PAGE 155

WEBER AIRCRAFT
5.4 &dy Support S e c t i o n Tests - Cant.
FIGURE 48
BODY SUPPORT SECTION DROP TEST 12
(DACRON 52 LACING WITH RUBBER LINED G R M T S )
REPORT NO. DR 5893

5 04 Body Support S e c t i o n T e s t a - Cont.
TABLE 23
-
--- --
SECONDARY -
. - LACING -.
STATIC .
--
LOAD -TESTS 12" SECTION
- - -. --- - -. -
No. of T h e o r e t i c a l 10) Test Elongat i o n Actual _ @

Test Lacing Lacing Lacing Breaking @ Break Lacing
No.
- Cord M a t e r i a l Crossrovers S t r e n n t h -1bs. (inches) Efficiency
1 Dacron Type 52 41(* 63.6 2.7 49.6
I1
2 41@ 63.6 1.8 46.3
11
3 41-(3 64.8 47.5
4 1.9 51.4
5 7 60 2.2 46.1
6 500 1.5 57.7
7 435 2.1 44.5
8 600 1.8 48 .o
9 1.5 53.9
10 1.7 68.1
11 2.6 64.4
12 2.4 64.4
13 9001- 2.4 69 a0
Braided cover of undrawn nylon.

Estane coated.
Lacing doubled and c r i s s - c r o s s i n c e n t e r of sample, s i n g l e l a c i n g on s i d e s .
Lacing doubled and c r o s s - c r o s s e d o v s r n e a r l y f u l l sample width.
S i n g l e sawtooth l a c i n g .
1 6 doubled and p a r a l l e l c r o s s o v e r s near c e n t e r of sample width only.
Lacing doubled and p a r a l l e l n e a r edges of sample, s i n g l e l a c e i n c e n t e r .
S t r a i g h t c r o s s over l a c i n g .
Standard saw t o o t h l a c i n g one end, s t r a i g h t cross-over h c i n g o t h e r end.
Assumes 61% s t r e n g t h effLciency i n l a c e d c o n f i g u r a t i o n .
Upper l a c i n g broke.
Upper l a c i n g r e p l a c e d and broke a g a i n .
Bottom l a c i n g broke.
Bottom l a c i n g replaced and broke a g a i n .
S t r a i g h t l a c i n g broke o u t .
Based on s t r e n g t h of i n d i v i d u a l cord.
WEBER AIRCRAFT
BURBANK; CALIFORNIA 91 503
5 .5 Body Support Design Sumnary
The completed secondary l a c i n g t e s t s and review of t h e
d e s i g n t e c h n i q u e s employed i n d e t e r m i n i n g t h e body s u p p o r t
configuration r e s u l t e d i n the following conclusions:
1. The drop t e s t s conducted a t Houston proved Dacron t o
be a good c h o i c e f o r a l a c i n g c o r d . Treatments had
l i t t l e e f f e c t on t h e t e s t r e s u l t s . The t e s t s
e x e m p l i f i e d t h e importance of p r o p e r l y p o s i t i o n i n g
t h e primary and secondary s u p p o r t s one w i t h t h e o t h e r .
2. P u l l t e s t s made on a 12" broad secondary s u p p o r t
s e c t i o n v e r i f i e d previous eonclusions t h a t the design
s t r e s s of a l a c i n g cord is approximately 65% of t h e
cords individual t e n s i l e breaking s t r e s s . The e l o n g -
a t i o n of the s e c t i o n was somewhat g r e a t e r than p r e -
v i o u s l y thought. Doubled up l a c i n g c o n f i g u r a t i o n s
a r e n o t a s r e l i a b l e a s t h e s i n g l e cord configuration.
3. A 4 p l y 1100 d e n i e r Type 52 Dacron cord w i l l be
adopted f o r t h e l a c i n g i n t h e couch p l a t f o r m . Two
p l y cord w i l l be used elsewhere. The d e n s i t y of
t h e secondary l a c i n g w i l l be reduced a s a f f e c t e d by
c o r r e c t i n g t h e a n t i c i p a t e d e l o n g a t i o n a t break i n t h e
design calculations.
4, The Houston d r o p t e s t s showed t h a t t h e a p p a r e n t draw
s t r e s e of t h e primary a t t e n u a t i n g c o r d s was i d e a l l y
2 A 0 pounds p e r cord end. The semi-production
p l a t f o r m 8 w i l l be designed t o a 2.10 pound draw s t r e s s

WEBER AIRCRAFT
I 5 .5 --
Body -
Support Design Sumnary (Continued)
(1.85 pounds c o r r e c t e d f o r bunching). The e x t r a
c o r d s may be e l i m i n a t e d by t h e r a t i o 2.10/2.40 if
found n e c e s s a r y d u r i n g subsequent tests. The 2.1
pound draw s t r e s s s h o u l d , however, r e s u l t i n a nominal
20-g a t t e n u a t i o n .
A sumnary of t e s t s conducted on t h e t w i s t e d c o r d , f i l a m e n t
wound body s u p p o r t s is p r e s e n t e d below. As can be s e e n
t h a t e x c e p t f o r t h e a d d i t i o n of t h e secondary l a c i n g t o
a t t a i n h i g h e r stasic load b e a r i n g c a p a b i l i t y , o n l y minor
changes have been made t o t h e i n i t i a l d e s i g n c o n f i g u r a t i o n
of t h e s e l e c t e d body s u p p o r t concept.
O r i g i n a l U n i t s (2) Phase I-A E v a l u a t i o n T e s t s
Design based on:
Weight d i s t r i b u t i o n p e r d e s i g n s p e c i f i c a t i o n s .
Body c r o s s s e c t i o n as s c a l e d from live human s u b j e c t s
Cord a t t e n u a t i n g s t r e s s of 1.78 pounds.
T e s t s made w i t h :
e Weber Drop Hamner
Weber 75 p e r c e n t i l e dummy weighted t o 220 pounds
1158 a t t e n u a t i n g c o r d s
Results - 18 t o 25 -g a t t e n u a t i o n
G to 7 -g s t a t i c load b e a r i n g c a p a b i l i t y

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & C O M P A N Y . INC.
5.5 Body Support Design Sumnary - Cont.

Prototype Support SIN 001
Design based on:
Weight d i s t r i b u t i o n p e r d e s i g n s p e c i f i c a t i o n s
Body c r o s s s e c t i o n as s c a l e d from A i r Force a n i
c i v i l i a n personnel.
Cord a t t e n u a t i n g s t r e s s o t 1.85 pounds
Balanced secondary l a c i n g f o r 225 pound dunany
T e s t made with:
Weber Drop Hamner
Weber 75 p e r c e n t i l e dunmy weighted t o 220 pounds
Results - i 7 t o 20 -g attenuation level
13 t o 14 -g s t a t i c load b e a r i n g c a p a b i l i t y
Prototype Support SIN 003
Design same a s SIN 001 s u p p o r t .
T e s t made with:
MSC drop tower
MSC 180 pound 7 5 p e r c e n t i l e dunmy
Test r e s u l t s - coach frame c o l l a p s e d a t 32 -g peak a t shoulde I

WEBER AIRCRAFT
DIV1'310N OF WALTER KlDDE & COMPANY. INC
- - -- - - -
5 ,: B O ~ YSupport Design Sunnnary - Cant.

T r o t o t y p e S u p p o r t s SIN 002, 004
Design based on:
Weight d i s t r i b u t i o n p e r Weber S p e c i f i c a t i o n based
on a 225 pound dumny
Body c r o s s s e c t i o n as s c a l e d from c i v i l i a n and
A i r Force p e r s o ~ w l
Cord a t t e n u a t i n g s t r e s s of 1.85 pcunds
Balanced secondary l a c i n g f o r 225 pound d m y
T e s t made w i t h :
MSC drop tower
MSC b o i l e r p l a t e couch frame
MSC 180 pound 75 p e r c e n t i l e dumny
Test r e s u l t s - Maximum a t t e n u a t i o n f o r c e s between 4 0 and
5 0 - g ' s were recorded a t head, s h o u l d e r s and l e g s of
dunmy, Non-uniform displacement of body members o c c u r r e d
P r o t o t y p e Supports SIN 005, 006
Design based on:
Weight d i s t r i b u t i o n p e r Weber 220 pound 75 p e r c e n t i l e
du-y
Body c r o s s s e c t i o n p e r Weber 220 pound 75 p e r c e n t i l e
d=y
Cord a t t e n u a t i n g stress o f 2.40 pouncbfor s h o u l d e r and
and arm, 2.10 pounds f o r t h e ra. nder 01 t h e s u p p o r t ,
Lacing rame as f o r coucher 001,.004
REPORT NO. - DR 5893 PAGE 161

WEBER AIRCRAFT
BURBf ?JK, CALIFORNIA 91 503
5.5 Body Support Design Sumnary - Cont.

MSC d r o p tower
MSC b o i l e r p l a t e and Weber couch frames
Weber 220 pound 75 p e r c e n t i l e d m y
P r o t e c t i v e f l a p s f o l d e d back o u t f tom under drmmy
Lacing on S / N 004, none on S/N 006
Results - 18 t o 19 -g a t t e n u a t i o n
S/N 005 (with l a c i n g ) produced high g- ' s p i k e ' force
(31.8 -g)
P r o t o t y p e Support S /N 007
Design based on:
Weight d i s t r i b u t i o n of Weber 220 pound 75 p e r c e n t i l e dumn]
Body c r o s s s e c t i o n of Weber 220 pound 75 p e r c e n t i l e dummy
Cord a t t e n u a t i n g stress of 2.76 pounds f o r s h o u l d e r and
arm, 2.42 pounds f o r remainder o f s u p p o r t
MSC d r o p tower
MSC b o i l e r p l a t e couch frame
Greber 220 pound 75 ~ r c e n t i l ed u m y
P r o t e c t i v e f l a p s f o l d e d back secondary l a c i n g removed
lest . . e s u l t s - e x c e l l e n t 16 LO 2 2 -g attenuation level

'JVEBER AIRCRAFT
DIVISION OF WALI'ER KlDDE & COMPANY. INC.
5.5 Body Support Design Sunmary - Cont.

Semi-Production Prototype (Deliverable Units1
Design biised on:
Weight distribution per design s p e c i f i c a t i o n s
Body crous s e c t i o n of 75 percentile Weber drarmy
Cord attenuating s t r e s s 2,10 pounds
Protective f l a p s removed
Dacron 52 lacing, 65% cord e f f i c i e n c y
Total ccrds 1177
REPORT NO. DR PAGE 163

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & C O M P A N Y . I N C .
6.0 CONCLUSIONS AND RECOMMEDATIONS

All objectives set forth i;l the initial phases of tb program
have been met or exceeded. The conccpt resulting from this

research and development effort warrants additional refinement
to produce an operational configuration, retaining the

present stowable and light weight features while adding multi-
directional crew restraint and support features. It is bclieved

that a qualified spacecraft, man-rated system, employing the
concept developed during this program, can be perfected for t h e
Apollo Camnand Module or other mnned space vehicles.
6.1 -
Conclusions
As a direct result of this developtent program the state-
of-the-art in crewmember support and restraint has been
substantially advanced. Specifically the developed
conccpt demonstrates the following:
9 Utilization of undrawn nylon fibers to attcnuntc
impact forces within the limits of human tolerance

is a practical method to afford crew protection from
emergency load conditions.
6 Undrawn nylon fibers eliminate crewmember post impact

rebound normally associated with netting type crew
support systems.
WEBER AIRCRAFT
6.1 Conclusions - Cont.

0 Uniform displacement of the occupants' body members,
during the attenuation mode, may be accomplished by
judicious placement of the energy absorbing undrawn
nylon cords,
b A body support and restraint which can adapt to 15th
through 90th percentile occupant sizes without
special adjustment provisions is practical.
* The permanent displacement, energy absorption action

required to eliminate post impact rebound can bc de-
layed until a desired force, less than the attenua-

tion level, is attained. This allows the occupant
to be subjected to normal launch, entry flight
forces and emergency entry and abort loads without
degradating the energy absorbing capability of the
system for emergency landing modes.
A floor mounted restraint system will adequately
restrain the crewmember to the moveable body support
platform.
o A one piece body support and restraint concept which
may be readily rcplaced and easily handled, if

necessary,in flight by the crewmember.

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & COMPANY. INC.
ti .l Conclusiofis - Cont .
e A framework system can be d e v i s e d t o a l l o w t h e
n e c e s s a r y occupant displacement f o r f o r c e a t tenua-
t i o n while s t i l l maintaining the required s t r u c t u r a l
integrity.
G F o l d a b l e couch a s s e m b l i e s which may be removed from
t h e suspension s t r u c t u r e and stowed i n t h e v e h i c l e
d u r i n g space f l i g h t .
I A couch system weight which is l e s s t h a n h a l f t h a t of
t h e p r e s e n t hard couch system i n c o r p o r a t e d i n t h e
Apolla Comnand Module.
6.2 Reconmendat i o n s
The i n h e r e n t weight s a v i n g s and stowable f e a t u r e s of t h i s
couch concept is p a r t i c u l a r i l y d e s i r a b l e f o r a p p l i c a t i o n
t o s e v e r a l t y p e s of space v e h i c l e s .
I t i s p a r t i c u l a r l y s u i t a b l e t o multi-man t r a n s 2 o r t - supply
and r e s c u e v e h i c l e s which may r e q u i r e t h r e e crewmembers
and, depending on m i s s i o n r e q u i r e m e n t s , c a r r y c a r g o t o a n
o r b i t i n g space s t a t i o n and r e t u r n w i t h f o u r o r f i v e
passengers, When ia cne cargo c o n f i g u r a t i o n the coucn
system may be stowed t o i t s minimum volume ciaximizing the
a l l o w a b l e volume f o r t h e cargo. The v e h i c l e may r e a d i l y
be converted t o t h e passenger c o n f i g u r a t i o n a t t h e space
s t a t i o n f o r the r e t u r n t r i p . On r e s c u e m i s s i o n s i t may be
found d e s i r a b l e t o d e s i g n t h e couch s o i t can be made i n t o

WEBER AIRCRAFT
C)IVISION O F WALTER KlDDE & COMPANY. INC
6.2 Recomnendations - Cont.

a l i t t e r f o r returning incapacitated passengers. The
l i t t e r c o n f i g u r a t i o n may a l s o be used f o r a s l e e p s t a t i o n
on extended m i s s i o n s .
The p r e s e n t Apollo Cornnand Module and v e h i c l e s under s t u d y
f o r Mars m i s s i o n s a r e l i m i t e d i n a v a i l a b l e space. Couches
which may be stowed i n t h e v e h i c l e w i l l permit more space
f o r e x e r c i s e , r e c r e a t i o n , s e t - u p and performance of
complex experiments .
The l i g h t weight and stowable couch developed under t h i s
c o n t r a c t , w i t h r e f i n e m e n t s , is i d e a l f o r a p p l i c a t i o n t o thess
t y p e s of space v e h i c l e s .
The c o n f i g u r a t i o n developed ta meet t h e o b j e c t i v e s of t h e
p r e s e n t program work s t a t e m e n t is l i m i t e d t o a p p l i c a t i o n of
l o a d s i n one a x i s , e y e b a l l s i n and o u t . However, t h e
a r t i c u l a t i o n requirements and stowable f e a t u r e s f o r a
t r a n s l u n a r m i s s i o n have been i n c o r p o r a t e d and a r e demon-
s t r a t e d by t h e developed couch.
Expansion of the l o a d s t o t h r e e a x i s c o n s i d e r a t i o n s and
s p e c i f i c d e f i n i t i o n of environmental requirements would
be t h e n e x t s t e p i n o b t a i n i n g a n o p e r a t i o n a l crew couch
system. Design v e r i f i c a t i o n t e s t s , i n c l u d i n g i n t e r g r a t i o n
tests i n t h e a p p l i c a b l e s p a c e c r a f t and impact t e s t s , w i t h

WEBER AIRCRAFT
6.2 Recoomuendations - Cont .

-
inertgal forces applied to simulate the critical load
condition6 in each axis of the spacecraft would be pre-
requsite to a final configurstion of a man-rated and space-
craft system.
6.2.1 Multidirectional Crew Couch Requirements
Predicated on application to a translunar mission with the
present Apollo Cammand Module configuration, Table 24
outlines the essential load requirements for the couch
system. Table 25 depicts the minimtan environmental
requirements for the system.
The couch geometry would be modified to allow the required
occupant displacement for attenuation of the emergency
landing impact forces inthe eyeballs up and down direction.
It may be found necessary however, to provide an attenuat-
ing structure in the eyeballs left and right directions
to reduce the impact forces. If it is found desirable to

incorporate this feature, it may be possible to adopt
the present Apollo hard couch Y-Y attenuation strut to the
system or, preferably, utilize the attenuating device
developed under the Manned Spacecraft Center contract
NAS 9-3533. This device employs a cyclic material
deformation concept of energy absorption which is
accomplished by rolling ductile tori elements in
friction contact be tween concentric tubes . The advantages

ssponse eloci t y
(-. 1 Force hange
0- --
16-g --
35-40 -g 30 FPS
Rebound . c
25-8 15 FPS
25-g 15 FPS

WEBER AIRCRAFT
TABLE 25
ENVIRONMENTAL CONDITIONS
-
. .. - APOLLO TRANSLUNAR-MISSION
RE-ENTRY SHELF &
PARAMETER LAUNCH FLIGHT & IMPACT EXPOSURE EEIERGERCY
Temperature
Atmosphere 85095% 85-95% 85095% Ambient Space Vacuum

o* 02 Q , 02 a
21.7 psia 5 psi. 5 to 21.7 14.7 psia log4 m Hg.
for 2 hours 288 hro. psia .5 nominal 100 hrs.
hrs (est)
Humidity 50% R.H. 40-70% 40-709, 10-100% 0 to 100%
Max. R.H. R.H. R.H. R.H.
Vibration 12.5 min.
from SPS
To Be 3etennined (3 Axis)
sec. - 10
Abort
Sand & Dust Design Consideration Only

Fungus Use Non-Nutrients or Treat with approved Fungicidal Agent
Salt Atmos. 1% Salt solution (by weight) for 48 hrs at 95"~, ambient
pressure
Ozone &sign Consideration Only
Nuclear Design Consideration Only
Radiation
Electromagnetic Design Consideration Only
Radiation
Meteoroids Design Consideration Only
Shock & Accel. See Table 24
Acoustics To Be Determined
1' Cabin Atmosphere (Nominal)
O2 4.638 psia. 92.76% Volume 93.49% Weight

C02 (max) .I47 psia 2.94% Volume 4.07% Weight
h t e r (Nm).215 psia 4.30% Volume 2.44% Weight

WEBER AIRCRAFT
DI'JISION OF WALTER KlDDE & COMPANY. INC
6.2.1 Multidirectional Crew Couch Requirements - Cont.

of this device over the present hard couch strut is
that the strut may be used in cyclic load applications
where load reversals may occur, the attenuation level
may be made readily adjustable, it is lighter in weight
and may be made more compact than the hard couch strut.
This strut may also be tested to determine its exact
output and reset capabilities prior to installation in
the spacecraft .
The body position adjustments of the couch frame would
be revised to be compatible with the present hard couch
system. These positions are:
96' Thigh-torso angle for launch, entry impact.
170' Thigh-torso angle for G b N station work.
270' Thigh torso a ~ g l efor access to the LEB
In addition, the center couch and the right hand couch
with their supporting structure will be configured to
allow disassembly and stowage while in space flight.
It is desirable that the disassemhly be accomplished
easily and without the use of special tools.

WEBER AIRCRAFT
DIVISION OF WALTER KlDDE & C O M P A N Y . I N C
6.2.2 Program P l a n - O p e r a t i o n a l A p o l l o C r e w Couch

F i g u r e 49 d i s p l a y s a n a p p r o x i m a t e s c h e d u l e r e q u i r e d
t o up g r a d e t h e p r e s e n t s y s t e m t o a n o p e r a t i o n a l s t a t u s .
It is d i v i d e d i n t o s e v e r a l t a s k s and p h a s e s t o p r o v i d e
m i l e s t o n e s by which t h e p r o g r e s s of t h e program may be
measured. An 1 8 month e f f o r t t o d e l i v e r t h e f i r s t
p r o d u c t i o n un! t i s c o n t e m p l a t e d .
Study Phase
The s t u d y phase is d i v i d e d i n t o t h r e e s u b t a s k s . The f i r s t
i s t o e s t a b l i s h f i r m o p e r a t i o n a l and ~ e r f o n n a n c er e q u i r e -
ments i n c l u d i n g l o a d s , e n v i r o n m e n t a l , a r t i c u l a t i o n . and
stowage f e a t u r e s . The i n t e r n a l arsangemenc of t h e
Coannand Module w i l l be reviewed t o d e f i n e t h e i n t e r f a c e
r e q u i r e m e n t s of t h e couch system. The work t o oe
ancomplished by e a c h crewrnemuer d u r i n g a t y p l c a l m i s s i o n
w i l l be reviewed t o a s s u r e couch c c m p a t i b i l i t y w i t h t h e
astronaut's tasks.
With t h e s e p a r a m e t e r s d e f i n e d , t h e second t a s k t o p r e p a r e
p r e l i m i n a r y l a y o u t s of t h e s y s t e m and e s t a b l i s h t h e b a s i c
f e a t u r e s o f t h e c o u c h e s and s u p p o r t s t r u c t u r e w i l l ue
accomplished. The t h i r d t a s k of t h e Study Phase w i l l be

t o f a b r i c a t e a mock-up o f t h e proposed c o n f i g u r a t i o n t o
r e - a f f i r n t h e b a s i c geometerical concept w i t h respect t o
a r t i c u l a t i o n , s t o w a b i l i t y , Conrnand Module i n t e r i a c e and
c o m p a t i b i l i t y w i t h t h e a s t r o n a u t s work t a s k s .
REPORT NO. DK 5893 PAGE

WEBER AIRCRAFT
BURBANK, CALIFORNIA 91 5Q3
6.2.2 Program Plan - O~erationalApollo Crew Couch - Cont.

Changes will be incorporated into the system. The
production design of the system will be established
and engineering drawings will be prepared. ThFs
effort will entail all t,he facets of design, reliability
and quality assurance necessary to provide an operational
system.
To verify the structural integrity of the couch and
multi-directional load capability of the concept, static
and dynamic loads will be applied to a single couch
structure and the results evaluated oefore fabrication
oi the qualification systems.
System iualif ication Phase
Preparation of the test plans and procedures will De
accomplished during the system design phase. These
documents will specify in detail all test conditions
and criteria to establish satisfactory completion of
the tests. If necessary, failure analysis will be nrsde
and the corrective action to be taken specified. Results
of all teats will be documented and submitted to the
National Aeronautics and Space Administration.

WEBER AIRCRAFT
DIVISION OF W A L T E R KlDDE & COMPANY. I N C .
b.2.2 Program Plan - Operational Apollo Crew Couch - Con:.

Completion and approval of the Qualification Phase
will initiate the Production Phase of the program.
Adoptation of the Quality Assurance and Control
functions employed by Weber in the production of the
Gemini Escape System will be used to provide the
necessary elements of control over the manufacture OF
the production units, . . . -ensurate with a man-ratea
aerospace system.

WEBER AIRCRAFT
DIVISIOK OF WALTER K l D D E & COMPANY. INC
REFERENCES
Weber S p c c i f i c a t i o n DR 5787, " U n i - d i r e c t i o n a l L i g h t w e i g h t Energy
Follow-on P r o j e c t c ! ' -
Absorbing Body Support P l a t f o r m f o r Use i n t h e b-pollo Couch System o r
D. Johansen, 30 September 1964.
Weber Report DR 5 788, " E v a l u a t i o n o f t h e U n i - d i r e c t i o n a l L i g h t w e i g h t

Energy Absorbing Bo4y Support P l a t form" -
W. S i e b e r , 30 September 1964.
Weber A i r c r a f t Report DR 5891, I1 Recortnnended U r . ? . - d i r e c t i o n a l , Energy

Absorbing Net Concept f o r C r e w Couches Used on t h e A p o l l o o r Follow-on
Projects" -I>. Johansen, 4 J a n u a r y 1965.
11
NASA G e n e r a l Working P a p e r 10,037, The Development and Q u a l i f i c a t i o n
Test'ng of a L i g h t Weight Net Couch and R e s t r a i n t System f o r Use i n t h e
Mercury S p a c e c r a f t " -
D. G e ~ e r ,J. S l i g h t , R. Marak, 'T. T u r n e r ,
22 September 1964.
NASA G ~ n e r a lWorking P a p e r 10,033, "Some D e c e l e r a t i o n T r a n s m i s s i o n

Charac e r i s t - i c s o f Nylon and Dacron R a s c h e l N e t t i n g and Somyk Loop
F a b r i c Under I n p a c t D e c e l e r a t i o i l , a t Impact V e l o c i t i e s o f 13.9 and 30
Fee: P e r second" - D . G e i e r , T. T u r n e r , 6 . S a l : , e r , 6 O c t o b e r 1964.
Veber A i r c r a f t T e s t Report TR- 303, "System and Dynamic Performance T e s t s

-
on t h e k t Couch Body S q p o r t System1' S . F i n g e r , 5 Januar:; 1 9 6 5 .
Weber A i r c r a f t Documentary F i l m , I! Development Tests,of a Light: Weight

E n e r g , Absorbing Crew Couch Systerc or Use i n t h e A p o l l o o r F o l l o c - o n
P r o j e c t S"
!:'eber A i r c r a f t Report DR 5866, " ~ e v e l o p m e n t o f A L i g h t Weight, Uni-

d i r e - t i o i l a l Net Type Couch System f o r t h e A p o l l o o r Follol -on ~ r c j e c t s l l -
9. Johansen, 8 March 1966.
Weber A i r c r a f t S p e c i f i c a t i o n DR 5799, I I S p e c i f i c a t i o n f o r a U n i - d i r e c t i o ~ a l
L i g h t Weighr Energy Absorbing Body Support and R e s t r a i n t f o r Use irt t h e
Apollo Couch System o r Follow-on 1 r o j e c t s " -D. J o h a n s e n , Januar;, 1965.
Weber A i r c r a f t T 2 s t Report ?R-332 I t S t a t i c , Dynamic and V i b r a t - o n

Performance T e s t s on t h e A p o l l o Net Couch Body Support System SK-1C343" -
C. G. K i ~ : g , 6 December 1965.

Phase I and II Final Report On The Development of A Net Couch Restraint System

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Phase I and II Final Report On The Development of A Net Couch Restraint System

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GPO

THE DEVELQPMWT OF A UNI-DIR.ECTIONAL LICI'HTWEIGNT ENERGY

NATIONAL AERONAUTICS AND SPACE ~ I N I S T R A X I Q N

C o n t r a c t No. WAS 9-3497

h i s r e p o r t was prepared by Weber A i r c r a f t , Division of Walter Kidde &

Company, Inc., 2820 Ontario S t r e e t , Burbank, C a l i f o r n i a , on National

Aeronautics and Space M m i n i o t r a t i o n Contract No. NAS 9-3497 "Uni-

d i r e c t i o n a l Lightweight Energy Absorbing Net Couch R e s t r a i n t System f o r

use i n t h e Apollo o r Follow-on Projects". The work was administered

under t h e d i r e c t i o n of t h e Crew Systems Division of t h e NASA Manned

Spacecraft Center with Mr. Douglas J. Geier, Head of t h e Acceleration

P r o j e c t s Section a c t i n g as Technical Nonitor.

This document i s prepared i n accordance with t h e Contract Schedule,

Bart VIII - Reports of Work, paragraph 3 - F i n a l Repart, and i a submitted

t o f u l f i l l the contractural obligation specified therein. A l l work on

t h i s developnmt program has been conducted by d i r e c t i o n of t h e Engineer-

i n g Department,, under t h e Weber A i r c r a f t P r o j e c t Number 537. This

document has a Weber A i s c r a f t Report No. DR 5893.

Weber A i r c r a f t wishes t o acknowledge t h e c o n t r i b u t i o n s of Mr. D. Johansen,

P r o j e c t Engineer a t Weber, and M r . M. Olson of t h e United state^ Rubber

Company under subcontract t o Weber, who were p r i m a r i l y r e s p o n s i b l e f o r

t h e development o f t h e Energy Abeorbing Net Couch - Restraint System.

REPORT NO. DR 5893 PAGE i

The developuent of t h e Apollo Energy Absorbing Net Couch - Restraint

August 1966. The F i n a l Report DR 5893 summarizes t h e t e c h n i c a l t a s k s

performed d u r i n g t h i s p e r i o d i n t h e d e s i g n , development, t e s t i n g and

f a b r i c a t i o n of a p r o t o t y p e system which would be i n t e r c h a n g e a b l e w i t h

t h e e x i s t i n g hard couch system i n t h e Apollo s p a c e c r a c t . The progran

was d i v i d e d i n t o two phases i d e n t i f i e d as a development phase and a

f a b r i c a t i o n phase. The development phase was p r o p o r t i o n e d t o t a k e

processing industry. These t e c h n i q u e s were u t i l i z e d t o d e v e l o p a body

s u p p o r t i n s e r t c o n c e p t which would a t t e n u a t e a 50-g impact f o r c e t o 20-g

a s f e l t by an anthropomorphic dummy. Three f a b r i c a t i o n tecl'niques, each

prepared by a d i f f e r e n t s u p p l i e r , were a n a l y z e d by Weber and e v a l u a t i o n

tests performed. A s a r e s u l t t h e t w i s t e d c o r d f i l a m e n t wound c o n s t r u c t i o n

concept, u t i l i z i n g undrawn nylon f i b e r s , was s e l e c t e d f o r t h e p r o t o t y p e

Phase I1 - F a b r i c a t i o n and T e s t of t h e Couch System - was provided first,

t o i n c o r p o r a t e m o d i f i c a t i o n s r e s u l t i n g from t h e Phase I tests; second, t o

perform a d d i t i o n a l tests; and t h i r d , t o d e s i g n and f a b r i c a t e a t h r e e man

couch system c a p a b l e o f b e i n g i n s t a l l e d i n t h e Apollo Comand Module.

A s a d i r e c t r e s u l t o f t h i s developmert program, i t may b e coccluded t h a t

t h e u s e o f undrawn nylon f i b e r s t o a t t e n u a t e impact f o r c e s w i t h i n t h e

REPORTNO. DR 5893 PAGE ii

l i m i t s of human t o l e r a n c e i a a very p r a c t i c a l method t o a f f o r d crew

p r o t e c t i o n from wergency load c o n d i t i o n s . The n e t couch system weight

i s l e s s than one h a l f t h a t of t h e p r e s e n t hard couch system and can b e

removed, folded, and s t o r e d i n t h e v e h i c l e d u r i n g space f l i g h t . All

o b j e c t i v e s set f o r t h i n t h e i n i t i a l phases of t h e program have been m e t

o r exceeded. It i s believed t h a t a q u a l i f i e d man-rated system employing

t h e concept developed, can h e p e r f e c t e d f o r t h e Apollo Comand Module o r

o t h e r Manned Space Vehicles. It i s estimated t h a t an 18 month program

would be required t o d e l i v e r t h e f i r s t o p e r a t i o n a l production Apollo system.

REPORT NO. DR 5893 PAGE iii

PHASE I-TASK A-DEVELOPMENT AND EVALUATION

Concept Evaluation Procedure

PHASE II - FABRICATION AND TEST

CONCLUSIONS AND RECOMMENDATIONS

REPORT NO. DR 5893 FAGE iv

2 Apollc N e t t i n g Type Couch Development P l a n 4

3 Woven F a b r i c Tape C o n s t r u c t i o n Concept 13

6 Load E l o n g a t i o n Curves f o r T r e a t e d Nylon and

8 Braided Cord K n i t t e d C o n s t r u c t i o n Cord Concept 35

10 S t r e s s - S t r a i n V a r i a t i o n s on 750 Denier Undrawn