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Document 02004D0090-20040204
Commission Decision of 23 December 2003 on the technical prescriptions for the implementation of Article 3 of Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC (notified under document number C(2003) 5041) (Text with EEA relevance) (2004/90/EC)
Consolidated text: Commission Decision of 23 December 2003 on the technical prescriptions for the implementation of Article 3 of Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC (notified under document number C(2003) 5041) (Text with EEA relevance) (2004/90/EC)
Commission Decision of 23 December 2003 on the technical prescriptions for the implementation of Article 3 of Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC (notified under document number C(2003) 5041) (Text with EEA relevance) (2004/90/EC)
2004D0090 — EN — 01.01.2004 — 000.001
This document is meant purely as a documentation tool and the institutions do not assume any liability for its contents
COMMISSION DECISION of 23 December 2003 on the technical prescriptions for the implementation of Article 3 of Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC (notified under document number C(2003) 5041) (Text with EEA relevance) (OJ L 031, 4.2.2004, p.21) |
Corrected by:
COMMISSION DECISION
of 23 December 2003
on the technical prescriptions for the implementation of Article 3 of Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC
(notified under document number C(2003) 5041)
(Text with EEA relevance)
(2004/90/EC)
THE COMMISSION OF THE EUROPEAN COMMUNITIES,
Having regard to the Treaty establishing the European Community,
Having regard to Directive 2003/102/EC of the European Parliament and of the Council relating to the protection of pedestrians and other vulnerable road users before and in the event of a collision with a motor vehicle and amending Directive 70/156/EEC ( 1 ), and in particular Article 3 thereof,
Whereas:
(1) |
Directive 2003/102/EC sets out the basic requirements in the form of tests and limit values for the Community type-approval of motor vehicles with regard to pedestrian protection. |
(2) |
Under that Directive, with a view to ensuring its uniform application by the competent authorities of the Member States, the technical prescriptions necessary to carry out the tests laid down in section 3.1 or 3.2 of Annex I to that Directive should be specified. |
(3) |
Those tests are based on the scientific work performed by the European Enhanced Vehicle Committee (EEVC); whereas the technical prescriptions to carry them out should also be based on the recommendations by the EEVC. |
HAS ADOPTED THIS DECISION:
Article 1
The technical prescriptions necessary to carry out the tests specified in section 3.1 and section 3.2 of Annex I to Directive 2003/102/EC are laid down in the Annex to this Decision.
Article 2
This Decision shall apply from 1 January 2004.
Article 3
This Decision is addressed to the Member States.
ANNEX
CONTENTS
PART I |
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1. |
General |
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2. |
Definitions |
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PART II |
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Chapter I |
General conditions applicable |
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Chapter II |
Lower legform to bumper tests |
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Chapter III |
Upper legform to bumper tests |
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Chapter IV |
Upper legform to bonnet leading edge tests |
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Chapter V |
Child/small adult headform to bonnet top tests |
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Chapter VI |
Adult headform to windscreen tests |
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Chapter VII |
Child and adult headform to bonnet top tests |
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APPENDIX I |
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1. |
Certification requirements |
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2. |
Lower legform impactor |
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3. |
Upper legform impactor |
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4. |
Headform impactors |
PART I
1. General
When performing measurements on a vehicle as described in this Part, the vehicle should be positioned in its normal ride attitude as described in point 2.3. If the vehicle is fitted with a badge, mascot or other structure which would bend back or retract under a low applied load, then such a load shall be applied before and/or while these measurements are taken. Any vehicle component which could change shape or position, such as ‘pop-up’ headlights, other than suspension components or active devices to protect pedestrians, shall be set to a shape or position that the test institutes, in consultation with the manufacturer, consider to be the most appropriate while taking these measurements.
2. Definitions
For the purposes of this Decision:
2.1. |
‘Vehicle type’ means a category of vehicles which, forward of the A-pillars, do not differ in such essential respects as: — the structure, — the main dimensions, — the materials of the outer surfaces of the vehicle, — the component arrangement (external or internal), in so far as they may be considered to have a negative effect on the results of the impact tests prescribed in Part II. Vehicles of category N1 described as being derived from M1 category refer to those vehicles of N1 category which, forward of the A-pillars, have the same general structure and shape as a pre-existing M1 category vehicle. |
2.2. |
‘Primary reference marks’ means holes, surfaces, marks and identification signs on the vehicle body. The type of reference mark used and the vertical (Z) position of each mark relative to the ground shall be specified by the vehicle manufacturer according to the running conditions specified in point 2.3. These marks shall be selected such as to be able to easily check the vehicle front and rear ride heights and vehicle attitude. If the primary reference marks are found to be within ± 25 mm of the design position in the vertical (Z) axis, then the design position shall be considered to be the normal ride height. ►C1 If this condition is not met, either the vehicle shall be adjusted to the design position, or all further measurements shall be adjusted, and tests performed, to simulate the vehicle being at the design position. ◄ |
2.3. |
‘Normal ride attitude’ is the vehicle attitude in running order positioned on the ground, with the tyres inflated to the recommended pressures, the front wheels in the straight-ahead position, with maximum capacity of all fluids necessary for operation of the vehicle, with all standard equipment as provided by the vehicle manufacturer, with a 75 kg mass placed on the driver's seat and with a 75 kg mass placed on the front passenger's seat, and with the suspension set for a driving speed of 40 km/h or 35 km/h in normal running conditions specified by the manufacturer (especially for vehicles with an active suspension or a device for automatic levelling). |
2.4. |
‘Ground reference level’ is the horizontal plane parallel to the ground level, representing the ground level for a vehicle placed at rest on a flat surface with the hand brake on, with the vehicle positioned in its normal ride attitude. |
2.5. |
‘Bumper’ is the front, lower, outer structure of a vehicle. It includes all structures that are intended to give protection to a vehicle when involved in a low speed frontal collision with another vehicle and also any attachments to this structure. The reference height and lateral limits of the bumper are identified by the corners and the bumper reference lines as defined in points 2.5.1 to 2.5.5.
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2.6. |
‘Bumper lead’ for any section of a car is the horizontal distance between the upper bumper reference line, as defined in point 2.5.1 and the bonnet leading edge reference line, as defined in point 2.9.2. |
2.7. |
‘Frontal upper surface’ is the outer structure that includes the upper surface of all outer structures except the windscreen, the A-pillars and structure rearwards of them. It therefore includes, but is not limited to, the bonnet, wings, scuttle, wiper spindle and lower windscreen frame. |
2.8. |
‘1 000 mm wrap around distance’ is the geometric trace described on the frontal upper surface by one end of a 1 000 mm long flexible tape, when it is held in a vertical fore and aft plane of the car and traversed across the front of the bonnet and bumper. The tape is held taut throughout the operation with one end held in contact with the ground, vertically below the front face of the bumper and the other end held in contact with the frontal upper surface (see Figure 3). The vehicle is positioned in the normal ride attitude. Similar procedures shall be followed, using alternative tapes of appropriate lengths to describe 1 500 and 2 100 mm wrap around distances. |
2.9. |
‘Bonnet top’ is the area which is bounded by (a), (b) and (c) as follows: (a) the bonnet leading edge reference line, as defined in point 2.9.2; (b) the bonnet side reference lines as defined in point 2.9.4; (c) the bonnet rear reference line as defined in point 2.9.7.
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2.10. |
‘Head performance criterion (HPC)’ shall be calculated from the resultant of accelerometer time histories as the maximum (depending on t1 and t2) of the equation:
where ‘a’ is the resultant acceleration as a multiple of ‘g’, and t1 and t2 are the two time instants (expressed in seconds) during the impact, defining the beginning and the end of the recording for which the value of HPC is a maximum. Values of HPC for which the time interval (t1 - t2) is greater than 15 ms are ignored for the purposes of calculating the maximum value. |
2.11. |
‘Windscreen’ is the frontal glazing of the vehicle which meets all the relevant requirements of Annex I to EU Directive 77/649/EEC.
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Figure 1a
Determination of upper bumper reference line
Figure 1b
Determination of lower bumper reference line
Figure 2
Determination of corner of bumper
Figure 3
Determination of wrap around distance
Figure 4
Determination of bonnet leading edge reference line
Figure 5
Determination of bonnet side refernce line
Figure 6
Determination of corner reference point; intersection of the bonnet leading edge reference line and the bonnet side reference line
Figure 7
Determination of bonnet rear reference line
Figure 8
Template design and markings used to join bonnet rear reference line and bonnet side reference line
Figure 9
Plan view of rear corner of bonnet — extending the bonnet rear reference line to meet the bonnet side reference line along the circumferential arc of template
Figure 10
Determination of rear windscreen reference line
PART II
CHAPTER I
General conditions applicable
1. Complete vehicle
1.1. |
Tests on complete vehicles shall comply with the conditions detailed in paragraphs 1.1.1, 1.1.2 and 1.1.3.
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2. Subsystem of vehicle
2.1. |
Where only a subsystem of the vehicle is supplied for tests, it shall comply with the conditions detailed in paragraphs 2.1.1, 2.1.2, 2.1.3 and 2.1.4.
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CHAPTER II
Lower legform to bumper tests
1. Scope
This test procedure is applicable to requirements under both Section 3.1 and Section 3.2 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The lower legform impactor for the bumper tests shall be in ‘free flight’ at the moment of impact. The impactor shall be released to free flight at such a distance from the vehicle that the test results are not influenced by contact of the impactor with the propulsion system during rebound of the impactor. |
2.2. |
The impactor may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in paragraphs 3.1.1.1 and 3.2.1.1 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
A minimum of three lower legform to bumper tests shall be carried out, one each to the middle and the outer thirds of the bumper at positions judged to be the most likely to cause injury. Tests shall be to different types of structure, where they vary throughout the area to be assessed. The selected test points shall be a minimum of 132 mm apart, and a minimum of 66 mm inside the defined corners of the bumper. These minimum distances are to be set with a flexible tape held tautly along the outer surface of the vehicle. The positions tested by the laboratories shall be indicated in the test report. |
3.3. |
Manufacturers might apply for derogation concerning an exemption zone for a removable towing hook. |
3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
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4. Lower Legform impactor
4.1. |
The diameter of the femur and tibia shall be 70 ± 1 mm and both shall be covered by foam ‘flesh’ and skin. The foam flesh shall be 25 mm thick Confor™ foam type CF-45. The skin shall be made of neoprene foam, faced with ½ mm thick nylon cloth both sides, with an overall thickness of 6 mm. |
4.2. |
The ‘centre of the knee’ is defined as the point about which the knee effectively bends. The ‘femur’ is defined as all components or parts of components (including flesh, skin covering, damper, instrumentation and brackets, pulleys, etc. attached to the impactor for the purpose of launching it) above the level of the centre of the knee. The ‘tibia’ is defined as all components or parts of components (including flesh, skin covering, instrumentation and brackets, pulleys, etc. attached to the impactor for the purpose of launching it) below the level of the centre of the knee. Note that the tibia as defined includes allowances for the mass etc. of the foot. |
4.3. |
The total mass of the femur and tibia shall be 8,6 ± 0,1 kg and 4,8 ± 0,1 kg respectively, and the total mass of the impactor shall be 13,4 ± 0,2 kg. The centre of gravity of the femur and tibia shall be 217 ± 10 mm and 233 ± 10 mm from the centre of the knee respectively. The moment of inertia of the femur and tibia, about a horizontal axis through the respective centre of gravity and perpendicular to the direction of impact, shall be 0,127 ± 0,010 kg/m2 and 0,120 ± 0,010 kg/m2 respectively. |
4.4. |
A uniaxial accelerometer shall be mounted on the non-impacted side of the tibia, 66 ± 5 mm below the knee joint centre, with its sensitive axis in the direction of impact. |
4.5. |
The impactor shall be instrumented to measure the bending angle and the shearing displacement between femur and tibia. |
4.6. |
A damper shall be fitted to the shear displacement system and may be mounted at any point on the rear face of the impactor or internally. The damper properties shall be such that the impactor meets both the static and dynamic shear displacement requirements and prevents excessive vibrations of the shear displacement system. |
Figure 1
Lower legform impactor with skin and foam covering
Figure 2
Lower legform to bumper tests for complete vehicle in normal ride attitude (left) and for complete vehicle or sub-system mounted on supports (right)
Figure 3
Tolerances of angles for the lower legform impactor at the time of first impact
CHAPTER III
Upper legform to bumper tests
1. Scope
This test procedure is applicable to requirements under both Section 3.1 and Section 3.2 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The upper legform impactor for the bumper test shall be mounted to the propulsion system, by a torque limiting joint, to prevent large off centre loads damaging the guidance system. The guidance system shall be fitted with low friction guides, insensitive to off-axis loading, that allow the impactor to move only in the specified direction of impact, when in contact with the vehicle. The guides shall prevent motion in other directions including rotation about any axis. |
2.2. |
The impactor may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in paragraphs 3.1.1.2 and 3.2.1.2 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
Upper legform to bumper tests shall be carried out to test positions selected in paragraph 3.2, Chapter II of this Part, if the lower bumper height at the test position is more than 500 mm and the manufacturer elects to perform an upper legform test instead of a lower legform test. In exceptional cases, and only with regard to the test procedure applicable under point 3.1.1.2 of Annex I of the Directive, manufacturers may apply for a derogation concerning the application of this alternative test to vehicles with a lower bumper height of less that 500 mm. |
3.3. |
Manufacturers may apply for derogation concerning an exemption zone for a removable towing hook. |
3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
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4. Upper legform impactor
4.1. |
The total mass of the upper legform impactor including those propulsion and guidance components which are effectively part of the impactor during the impact shall be 9,5 kg ± 0,1 kg. The upper legform impactor mass may be adjusted from this value by up to ± 1 kg, provided the required impact velocity is also changed using the formula:
where V = impact velocity (m/s) M = mass (kg), measured to an accuracy of better than ± 1 % |
4.2. |
The total mass of the front member and other components in front of the load transducer assemblies, together with those parts of the load transducer assemblies in front of the active elements, but excluding the foam and skin, shall be 1,95 ± 0,05 kg. |
4.3. |
The foam shall be two sheets of 25 mm thick ConforTM foam type CF-45. The skin shall be a 1,5 mm thick fibre reinforced rubber sheet. The foam and rubber skin together shall weigh 0,6 ± 0,1 kg (this excludes any reinforcement, mountings, etc. which are used to attach the rear edges of the rubber skin to the rear member). The foam and rubber skin shall be folded back towards the rear, with the rubber skin attached via spacers to the rear member so that the sides of the rubber skin are held parallel. The foam shall be of such a size and shape that an adequate gap is maintained between the foam and components behind the front member, to avoid significant load paths between the foam and these components. |
4.4. |
The front member shall be strain gauged to measure bending moments in three positions, as shown in Figure 4a, each using a separate channel. The strain gauges are located on the impactor on the back of the front member. The two outer strain gauges are located 50 ± 1 mm from the impactor's symmetrical axis. The middle strain gauge is located on the symmetrical axis with a ± 1 mm tolerance. |
4.5. |
The torque limiting joint shall be set so that the longitudinal axis of the front member is perpendicular to the axis of the guidance system, with a tolerance of ± 2°, with the joint friction torque set to a minimum of 650 Nm. |
4.6. |
The centre of gravity of those parts of the impactor which are effectively forward of the torque limiting joint, including any weights fitted, shall lie on the longitudinal centre line of the impactor, with a tolerance of ± 10 mm. |
4.7. |
The length between the load transducer centre lines shall be 310 ± 1 mm and the front member diameter shall be 50 ± 1 mm. |
Figure 4a
Upper legform impactor
CHAPTER IV
Upper legform to bonnet leading edge tests
1. Scope
This test procedure is applicable to requirements under both Section 3.1 and Section 3.2 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The upper legform impactor for the bonnet leading edge test shall be mounted to the propulsion system, by a torque limiting joint, to prevent large off centre loads damaging the guidance system. The guidance system shall be fitted with low friction guides, insensitive to off-axis loading, that allow the impactor to move only in the specified direction of impact, when in contact with the vehicle. The guides shall prevent motion in other directions including rotation about any axis. |
2.2. |
The impactor may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in points 3.1.3 and 3.2.3 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
A minimum of three upper legform to bonnet leading edge tests shall be carried out, one each to the middle and the outer thirds of the bonnet leading edge at positions judged to be the most likely to cause injury. However, the test point in each third shall be selected such that the required kinetic energy of impact, determined in point 3.4.2.7, exceeds 200 J, if such a point is available. Tests shall be to different types of structure, where they vary throughout the area to be assessed. The selected test points shall be a minimum of 150 mm apart, and a minimum of 75 mm inside the defined corner reference points. These minimum distances are to be set with a flexible tape held tautly along the outer surface of the vehicle. The positions tested by the laboratories shall be indicated in the test report. |
3.3. |
All standard equipment fitted to the front end of the vehicle shall be in position. |
3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
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4. Upper legform impactor
4.1. |
The total mass of the front member and other components in front of the load transducer assemblies, together with those parts of the load transducer assemblies in front of the active elements, but excluding the foam and skin, shall be 1,95 ± 0,05 kg. |
4.2. |
The foam shall be two sheets of 25 mm thick Confor™ foam type CF-45. The skin shall be a 1,5 mm thick fibre reinforced rubber sheet. The foam and rubber skin together shall weigh 0,6 ± 0,1 kg (this excludes any reinforcement, mountings, etc. which are used to attach the rear edges of the rubber skin to the rear member). The foam and rubber skin shall be folded back towards the rear, with the rubber skin attached via spacers to the rear member so that the sides of the rubber skin are held parallel. The foam shall be of such a size and shape that an adequate gap is maintained between the foam and components behind the front member, to avoid significant load paths between the foam and these components. |
4.3. |
The front member shall be strain gauged to measure bending moments in three positions, as shown in Figure 4b, each using a separate channel. The strain gauges are located on the impactor on the back of the front member. The two outer strain gauges are located 50 ± 1 mm from the impactor's symmetrical axis. The middle strain gauge is located on the symmetrical axis with a ± 1 mm tolerance. |
4.4. |
The torque limiting joint shall be set so that the longitudinal axis of the front member is perpendicular to the axis of the guidance system, with a tolerance of ± 2°, with the joint friction torque set to a minimum of 650 Nm. |
4.5. |
The centre of gravity of those parts of the impactor which are effectively forward of the torque limiting joint, including any weights fitted, shall lie on the longitudinal centre line of the impactor, with a tolerance of ± 10 mm. |
4.6. |
The length between the load transducer centrelines shall be 310 ± 1 mm and the front member diameter shall be 50 ± 1 mm. |
Figure 4b
Upper legform impactor
Figure 5
Upper legform to bonnet leading edge tests
Figure 6
Velocity of upper legform to bonnet leading edge tests with respect to vehicle shape
Notes:
1. Interpolate horizontally between curves.
2. With configurations below 20 km/h — test at 20 km/h.
3. With configurations above 40 km/h — test at 40 km/h.
4. With negative bumper leads — test as for zero bumper lead.
5. With bumper leads above 400 mm — test as for 400 mm.
Figure 7
Angle of upper legform to bonnet leading edge tests with respect to vehicle shape
Key:
A = 0 mm bumper lead
B = 50 mm bumper lead
C = 150 mm bumper lead
Notes
1. Interpolate vertically between curves.
2. With negative bumper leads — test as for zero bumper lead.
3. With bumper leads above 150 mm — test as for 150 mm.
4. With bonnet leading edge heights above 1 050 mm — test as for 1 050 mm.
Figure 8
Kinetic energy of upper legform to bonnet leading edge tests with respect to vehicle shape
Key:
A = 50 mm bumper lead
B = 100 mm bumper lead
C = 150 mm bumper lead
D = 250 mm bumper lead
E = 350 mm bumper lead
Notes
1. Interpolate vertically between curves.
2. With bumper leads below 50 mm — test as for 50 mm.
3. With bumper leads above 350 mm — test as for 350 mm.
4. With bonnet leading edge heights above 1 050 mm — test as for 1 050 mm.
5. With a required kinetic energy above 700 J — test at 700 J.
6. With a required kinetic energy equal to or below 200 J — no test is required.
CHAPTER V
Child/small adult headform to bonnet top tests
1. Scope
This test procedure is applicable to the requirements of Section 3.1 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The headform impactor for the bonnet top test shall be in ‘free flight’ at the moment of impact. The impactor shall be released to free flight at such a distance from the vehicle that the test results are not influenced by contact of the impactor with the propulsion system during rebound of the impactor. |
2.2. |
The impactor may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in point 3.1.2 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
Headform impactor tests shall be to the bonnet top as defined in paragraph 2.9 of Part I. A minimum of eighteen tests shall be carried out with the headform impactor, six tests each to the middle and the outer thirds of the bonnet top, as described in point 2.9.8 of Part I, at positions judged to be the most likely to cause injury. Tests shall be to different types of structure, where these vary throughout the area to be assessed. Among the minimum of eighteen tests, at least twelve tests shall be carried out with the headform impactor within the ‘Bonnet Top Zone A’ and a minimum of six tests shall be carried out within the ‘Bonnet Top Zone B’ as defined in paragraph 3.3. The test points shall be located so that the impactor is not expected to impact the bonnet top with a glancing blow and then impact the windscreen or an A pillar more severely. The selected test points for the child/small adult headform impactor shall be a minimum of 165 mm apart, a minimum of 82,5 mm inside the defined bonnet side reference lines, a minimum of 82,5 mm forwards of the defined bonnet rear reference line. Each selected test point for the child/small adult headform shall also be a minimum of 165 mm rearwards of the bonnet leading edge reference line, unless no point in the bonnet leading edge test area within 165 mm laterally would, if chosen for an upper legform to bonnet leading edge test, require a kinetic energy of impact of more than 200 J. These minimum distances are to be set with a flexible tape held tautly along the outer surface of the vehicle. If a number of test positions have been selected in order of potential to cause injury and the test area remaining is too small to select another test position while maintaining the minimum spacing between tests, then less than eighteen tests may be performed. The positions tested by the laboratories shall be indicated in the test report. However, the technical services conducting the tests shall perform as many tests as necessary to guarantee the compliance of the vehicle with the head protection criteria (HPC) limit values of 1 000 for ‘bonnet top zone A’ and 2 000 for ‘bonnet top zone B’, especially in the points near to the borders between the two types of zones. |
3.3. |
‘Bonnet top zone A’ and ‘bonnet top zone B’
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3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
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4. Child/small adult headform impactor
4.1. |
The child/small adult headform impactor is a sphere made of aluminium and of homogenous construction. |
4.2. |
The sphere shall be covered with a 13,9 ± 0,5 mm thick synthetic skin, which shall cover at least half of the sphere. |
4.3. |
The centre of gravity of the child/small adult headform impactor, including instrumentation, shall be located in the centre of the sphere with a tolerance of ± 5 mm. The moment of inertia about an axis through the centre of gravity and perpendicular to the direction of impact shall be 0,010 ± 0,0020 kg/m2. |
4.4. |
A recess in the sphere shall allow for mounting one triaxial or three uniaxial accelerometers. The accelerometers shall be positioned according points 4.4.1 and 4.4.2.
|
Figure 10
Child/small adult headform impactor (dimensions in mm)
CHAPTER VI
Adult headform to windscreen tests
1. Scope
This test procedure is applicable to requirements under Section 3.1 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The headform impactor for the windscreen top test shall be in ‘free flight’ at the moment of impact. The impactor shall be released to free flight at such a distance from the vehicle that the test results are not influenced by contact of the impactor with the propulsion system during rebound of the impactor. |
2.2. |
The impactor may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in point 3.1.4 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
The adult headform impactor tests shall be to the windscreen. A minimum of five tests shall be carried out with the headform impactor at positions judged to be the most likely to cause injury. The selected test points for the adult headform impactor to the windscreen shall be a minimum of 165 mm apart, a minimum of 82,5 mm inside the windscreen limits as defined in Directive 77/649/EEC and a minimum of 82,5 mm forwards of the rear windscreen reference line as defined in point 2.11.1 of Part I (see Figure 11). These minimum distances are to be set with a flexible tape held tautly along the outer surface of the vehicle. If a number of test positions have been selected in order of potential to cause injury and the test area remaining is too small to select another test position while maintaining the minimum spacing between tests, then less than five tests may be performed. The positions tested by the laboratories shall be indicated in the test report. |
3.3. |
Within the area described in point 3.2 all areas are to be considered in the same manner. |
3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
|
4. Adult headform inpactor
4.1. |
The adult headform impactor is a sphere made of aluminium and of homogenous construction. |
4.2. |
The sphere shall be covered with a 13,9 ± 0,5 mm thick synthetic skin, which shall cover at least half of the sphere. |
4.3. |
The centre of gravity of the adult headform impactor, including instrumentation, shall be located in the centre of the sphere with a tolerance of ± 5 mm. The moment of inertia about an axis through the centre of gravity and perpendicular to the direction of impact shall be 0,0125 ± 0,0010 kg/m2. |
4.4. |
A recess in the sphere shall allow for mounting one triaxial or three uniaxial accelerometers. The accelerometers shall be positioned according to points 4.4.1 and 4.4.2.
|
Figure 11
Windscreen impact area
Figure 12
Adult headform impactor (dimensions in mm)
CHAPTER VII
Child and adult headform to bonnet top tests
1. Scope
This test procedure is applicable to Section 3.2 of Annex I of the Directive 2003/102/EC.
2. General
2.1. |
The headform impactors for the bonnet top tests shall be in ‘free flight’ at the moment of impact. The impactors shall be released to free flight at such a distance from the vehicle that the test results are not influenced by contact of the impactors with the propulsion system during rebound of the impactors. |
2.2. |
The impactors may be propelled by an air, spring or hydraulic gun, or by other means that can be shown to give the same result. |
3. Specification of the test
3.1. |
The purpose of the test is to ensure that the requirements given in points 3.2.2 and 3.2.4 of Annex I of the Directive 2003/102/EC are fulfilled. |
3.2. |
Headform impactor tests shall be to the bonnet top as defined in point 2.9 of Part I. Tests to the forward section of the bonnet top defined in point 3.4.2.3 shall be with a child headform impactor defined in point 3.4.1.1. Tests to the rearward section of the bonnet top defined in point 3.4.2.4 shall be with an adult headform impactor, defined in point 3.4.1.1. A minimum of nine tests shall be carried out with each headform impactor, three tests each to the middle and the outer thirds of the forward and rearward bonnet top sections, as described in point 2.9.8 of Part I, at positions judged to be the most likely to cause injury. Tests shall be to different types of structure, where these vary throughout the area to be assessed. |
3.3. |
The selected test points for the adult headform impactor shall be a minimum of 165 mm apart, a minimum of 82,5 mm inside the defined bonnet side reference lines and a minimum of 82,5 mm forwards of the defined bonnet rear reference line. The test points shall be located so that the impactor is not expected to impact the bonnet top with a glancing blow and then impact the windscreen or an A pillar more severely. The selected test points for the child headform impactor shall be a minimum of 130 mm apart, a minimum of 65 mm inside the defined bonnet side reference lines, a minimum of 65 mm forwards of the defined bonnet rear reference line. Each selected test point for the child headform shall also be a minimum of 130 mm rearwards of the bonnet leading edge reference line, unless no point in the bonnet leading edge test area within 130 mm laterally would, if chosen for an upper legform to bonnet leading edge test, require a kinetic energy of impact of more than 200 J. These minimum distances are to be set with a flexible tape held tautly along the outer surface of the vehicle. If a number of test positions have been selected in order of potential to cause injury and the test area remaining is too small to select another test position while maintaining the minimum spacing between tests, then less than nine tests may be performed. The positions tested by the laboratories shall be indicated in the test report. |
3.4. |
Test method 3.4.1. Test apparatus
3.4.2. Test procedure
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4. Headform impactors
4.1. Adult headform impactor
4.1.1. |
The adult headform impactor is a sphere made of aluminium and of homogenous construction. |
4.1.2. |
The sphere shall be covered with a 13,9 ± 0,5 mm thick synthetic skin, which shall cover at least half of the sphere. |
4.1.3. |
The centre of gravity of the adult headform impactor, including instrumentation, shall be located in the centre of the sphere with a tolerance of ± 5 mm. The moment of inertia about an axis through the centre of gravity and perpendicular to the direction of impact shall be 0,0125 ± 0,0010 kg/m2. |
4.1.4. |
A recess in the sphere shall allow for mounting one triaxial or three uniaxial accelerometers. The accelerometers shall be positioned according points 4.1.4.1 and 4.1.4.2.
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4.2. Child headform impactor
4.2.1. |
The child headform impactor is a sphere made of aluminium and of homogenous construction. |
4.2.2. |
The sphere shall be covered with a 11,0 ± 0,5 mm thick synthetic skin, which shall cover at least half of the sphere. |
4.2.3. |
The centre of gravity of the child headform impactor, including instrumentation, shall be located in the centre of the sphere with a tolerance of ± 5 mm. The moment of inertia about an axis through the centre of gravity and perpendicular to the direction of impact shall be 0,0036 ± 0,0003 kg/m2. |
4.2.4. |
A recess in the sphere shall allow for mounting one triaxial or three uniaxial accelerometers. The accelerometers shall be positioned according to points 4.2.4.1 and 4.2.4.2.
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Figure 13
Adult headform impactor (dimensions in mm)
Figure 14
Child headform impactor (dimensins in mm)
Appendix I
CERTIFICATION OF IMPACTORS
1. Certification requirements
1.1. |
The impactors that are used in the tests detailed in Part II are required to comply with appropriate performance requirements. The requirements for the lower legform impactor are specified in Section 2; the upper legform impactor requirements are specified in Section 3 and the adult, child and child/small adult headform impactor requirements are specified in Section 4. |
2. Lower legform impactor
2.1. Static tests
2.1.1. |
The lower legform impactor shall meet the requirements specified in point 2.1.2 when tested as specified in point 2.1.4 and the impactor shall meet the requirements specified in point 2.1.3 when tested as specified in point 2.1.5. For both tests the impactor shall have the intended orientation about its longitudinal axis, for the correct operation of its knee joint, with a tolerance of ± 2°. The stabilised temperature of the impactor during certification shall be 20 °C ± 2 °C. The CAC response values, as defined in ISO 6487:2000, shall be 50° for the knee bending angle and 500 N for the applied force when the impactor is loaded in bending in accordance with point 2.1.4, and 10 mm for the shearing displacement and 10 kN for the applied force when the impactor is loaded in shearing in accordance with point 2.1.5. For both tests low-pass filtering at an appropriate frequency is permitted, to remove higher frequency noise without significantly affecting the measurement of the response of the impactor. |
2.1.2. |
When the impactor is loaded in bending in accordance with point 2.1.4, the applied force/bending angle response shall be within the limits shown in Figure 1. Also, the energy taken to generate 15,0° of bending shall be 100 ± 7 J. |
2.1.3. |
When the impactor is loaded in shearing in accordance with point 2.1.5, the applied force/shearing displacement response shall be within the limits shown in Figure 2. |
2.1.4. |
The legform impactor, without foam covering and skin, shall be mounted with the tibia firmly clamped to a fixed horizontal surface and a metal tube connected firmly to the femur, as shown in Figure 3. To avoid friction errors, no support shall be provided to the femur section or the metal tube. The bending moment applied at the centre of the knee joint, due to the weight of the metal tube and other components (excluding the legform itself), shall not exceed 25 Nm. A horizontal normal force shall be applied to the metal tube at a distance of 2,0 ± 0,01 m from the centre of the knee joint and the resulting angle of knee deflection shall be recorded. The load shall be increased until the angle of deflection of the knee is in excess of 22°. The energy is calculated by integrating the force with respect to the bending angle in radians, and multiplying by the lever length of 2,0 ± 0,01 m. |
2.1.5. |
The impactor, without foam covering and skin, shall be mounted with the tibia firmly clamped to a fixed horizontal surface and a metal tube connected firmly to the femur and restrained at 2,0 m from the centre of the knee joint, as shown in Figure 4. A horizontal normal force shall be applied to the femur at a distance of 50 mm from the centre of the knee joint and the resulting knee shearing displacement shall be recorded. The load shall be increased until the shearing displacement of the knee is in excess of 8,0 mm or the load is in excess of 6,0 kN. |
2.2. Dynamic tests
2.2.1. |
The lower legform impactor shall meet the requirements specified in point 2.2.2 when tested as specified in point 2.2.4. The stabilised temperature of the impactor during certification shall be 20 °C ± 2 °C. |
2.2.2. |
When the impactor is impacted by a linearly guided certification impactor, as specified in point 2.2.4, the maximum upper tibia acceleration shall be not less than 120 g and not more than 250 g. The maximum bending angle shall be not less than 6,2° and not more than 8,2°. The maximum shearing displacement shall be not less than 3,5 mm and not more than 6,0 mm. For all these values the readings used shall be from the initial impact with the certification impactor and not from the arresting phase. Any system used to arrest the impactor or certification impactor shall be so arranged that the arresting phase does not overlap in time with the initial impact. The arresting system shall not cause the transducer outputs to exceed the specified CAC. |
2.2.3. |
The instrumentation response value CFC, as defined in ISO 6487:2000, shall be 180 for all transducers. The CAC response values, as defined in ISO 6487:2000, shall be 50° for the knee bending angle, 10 mm for the shearing displacement and 500 g for the acceleration. This does not require that the impactor itself be able to physically bend and shear to these angles and displacements. |
2.2.4 |
Test procedure
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3. Upper legform impactor
3.1. |
The upper legform impactor shall meet the requirements specified in point 3.2 when tested as specified in point 3.3. The stabilised temperature of the impactor during certification shall be 20 °C ± 2 °C. |
3.2. |
Requirements
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3.3. |
Test procedure
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4. Headform impactors
4.1. |
The child, child/small adult and the adult headform impactors shall meet the requirements specified in point 4.2 when tested as specified in point 4.3. The stabilised temperature of the impactors during certification shall be 20 °C ± 2 °C. |
4.2. |
Requirements
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4.3. |
Test procedure
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( 1 ) OJ L 321, 6.12.2003, p. 15.