2006/444/EG: Beschluss des Rates vom 13. März 2006 über den Beitritt der Gemeinschaft zu Regelung Nr. 55 der Wirtschaftskommission der Vereinten Nationen für Europa über einheitliche Bedingungen für die Genehmigung mechanischer Verbindungsteile von Fahrzeugkombinationen (Text von Bedeutung für den EWR)

Durchsuchbarer Text in vereinfachter Darstellung. Tabellen, Abbildungen und verbindliche Gestaltung bitte anhand der Originaldateien prüfen.

cluding the tested device. With asynchronous testing the frequencies of the two force components shall be between approximately 1 per cent and a maximum of 3 per cent apart. For coupling devices made from steel the number of stress cycles is 2 × 106. For devices made from materials other than steel a higher number of cycles may be necessary. The dye‐penetration method of crack testing or an equivalent method shall be used to determine any cracking during test. 2.3. With pulsating tests, the test force varies between the maximum test force and a lower, minimum, test force, which may not be greater than 5 per cent of the maximum test force unless otherwise stated in the specific testing procedure. 2.4. With static tests, other than the special tests required by paragraph 3.2.3 of this annex, the test force shall be applied smoothly and quickly and be maintained for at least 60 seconds. 2.5. The coupling devices or component on test should normally be mounted as rigidly as possible on a test rig in the actual position in which they will be used on the vehicle. The fixing devices should be those specified by the manufacturer or applicant and should be those intended for the attachment of the coupling device or component to the vehicle and/or shall have identical mechanical characteristics. 2.6. Coupling devices or components shall be tested in the form used on the road. However, at the discretion of the manufacturer, and in agreement with the technical service, flexible components may be neutralised if this is necessary for the test procedure and if this will not have any unrealistic influence on the test result. Flexible components which are overheated during these accelerated test procedures may be replaced during the test. The test loads may be applied by means of special slack‐free devices. 3. SPECIFIC TESTING REQUIREMENTS 3.1. Coupling balls and towing brackets 3.1.1. Mechanical coupling devices with coupling balls may be of the following types: (i) one‐piece coupling balls including devices with noninterchangeable detachable balls (see Figures 20a and 20b), (ii) coupling balls, comprising a number of parts which can be dismantled (see Figures 20c, 20d and 20e), (iii) towing brackets without ball fitted (see Figure 20f). Figure 20 Arrangements of ball type towing brackets Text von Bild a One piece towing bracket and coupling ball. b The ball unit on the above may be detachable by hand without the use of tools, for example, a bayonet fitting. f c Towing bracket with ball detachable by the use of tools. f e d Towing bracket with detachable ball on an integral support, for example, a Class A50 bolt-on ball. f e e Towing bracket with ball detachable by the use of tools. f e f Towing bracket without fitted ball unit. 3.1.2. The basic test is a dynamic endurance test. The test sample comprises the coupling ball, the ball neck and the mountings necessary for attaching the assembly to the vehicle. The coupling ball and towing bracket shall be rigidly mounted to a test rig, capable of producing an alternating force, in the actual position in which it is intended for use. 3.1.3. The positions of the fixing points for attaching the coupling ball and towing bracket are specified by the vehicle manufacturer (see paragraph 5.3.2 of this Regulation). 3.1.4. The devices submitted for test shall be provided with all parts and design details which may have an influence on the strength criteria (for example electrical socket plate, any marking, etc.). The test sample shall include all parts up to the anchorage points or fitting points to the vehicle. The geometric location of the coupling ball and the fixing points of the coupling device related to the reference line shall be provided by the vehicle manufacturer and shall be shown in the test report. All relative positions of the anchorage points with respect to the reference line, for which the towing vehicle manufacturer shall provide all the necessary information to the towing device manufacturer, shall be repeated on the test bed. 3.1.5. The sample mounted on the test rig shall be subjected to an alternating stress test applied at an angle to the ball as shown in Figure 21 or 22. The direction of the angle of test shall be determined by the vertical relationship between a horizontal reference line passing through the centre of the ball and a horizontal line passing through the fixing point of the coupling device which is the highest of the nearest, when measured in a horizontal plane, to a transverse vertical plane passing through the centre of the ball. If the fixing point line is above the horizontal reference line, the test shall be carried out at an angle of α = + 15o ±1o and if it is below then the test shall be carried out at an angle of α = - 15o ±1o (see Figure 21). The fixing points to be considered in determining the angle of test shall be those declared by the vehicle manufacturer and which transmit the major towing forces to the structure of the towing vehicle. This angle is chosen in order to take account of the vertical static and dynamic load and is only applicable for a permitted static vertical load not exceeding: S = 120 × D [N] Where the static vertical load exceeds that calculated above, the angle shall, in both conditions, be increased to 20o. The dynamic test shall be performed with the following test force: Fhs res = ±0.6 D 3.1.6. The test procedure is applicable to the different types of coupling devices (see paragraph 3.1.1 of this annex) as follows: 3.1.6.1. one piece coupling balls including devices with non‐interchangeable detachable balls (see Figures 20a and 20b). 3.1.6.1.1. the strength test for the devices shown in Figures 20a and 20b shall be carried out according to the requirements of paragraph 3.1.5; Figure 21 Angles of application of test force Text von Bild α = -15°±1° α Fhs res Fhs res α α = +15°±1° Note: The line parallel to the reference line passes through the centre of the highest and nearest point for mounting the towing bracket to the vehicle - see Annex 6, paragraph 3.1.5. Figure 22 Angles of application of test force Text von Bild fmax fmin fmax fmin fmax fmin emax emax emax Note: Direction of alternating test force, Fhs res, depending on the location of the ball centre horizontal reference line in relation to the line parallel to this referece line - See Figure 21. 3.1.6.2. coupling balls, comprising parts which can be dismantled. The following categories are defined: (a) towing bracket and ball (see Figure 20c), (b) towing bracket and ball on integral support (see Figure 20d), (c) towing bracket with detachable ball (see Figure 20e), (d) towing bracket without ball (see Figure 20f). 3.1.6.2.1. The strength test for the devices shown in Figures 20c to 20f shall be carried out according to the requirements of paragraph 3.1.5. Dimensions e and f, shall have a manufacturing tolerance of ±5 mm, and shall be stated in the test report. The test of the towing bracket (see Figure 20f) shall be carried out with a mounted ball (on support). Account will be taken only of the result of the test on the towing bracket between the fixing points and the mounting surface of the ball support. The dimensions e and f shall have a manufacturing tolerance of ±5 mm and shall be specified by the coupling device manufacturer. 3.1.6.3. Coupling devices with variable dimensions e and f for demountable and interchangeable coupling balls — see Figure 22. 3.1.6.3.1. The strength tests for such towing brackets shall be carried out to the requirements of paragraph 3.1.5. 3.1.6.3.2. If a worst case configuration can be defined by agreement between the manufacturer and the type approval authority or technical service, then testing of this one configuration alone shall be sufficient. Otherwise, several ball positions shall be tested in a simplified test programme according to paragraph 3.1.6.3.3. 3.1.6.3.3. In a simplified test programme, the value for f shall be between a defined value of fmin and a value of fmax which does not exceed 100 mm. The ball shall be at a distance, emax, of 130 mm from the support. To cover all possible positions of the ball, in the field given by the horizontal distance from the mounting surface and the vertical range of f (fmin to fmax), two devices are to be tested: (i) one with a ball in the upper (fmax) position, and (ii) one with a ball in the lower (fmin) position. The angle of application of the test force will vary, positive or negative, depending on the relationship of the ball centre horizontal reference line to the parallel line passing through the highest and nearest coupling device fixing point. The angles to be used are shown in Figure 22. 3.1.7. In the case where detachable ball units are retained using fixing arrangements other than screwed fittings, for example, spring clips, and where the positive mechanical engagement aspect of the arrangement is not tested during the dynamic test, then the arrangement shall be subject to a static test applied to the ball or to the positive mechanical engagement arrangement in an appropriate direction. Where the positive mechanical engagement arrangement retains the ball unit vertically, the static test shall be to apply an upwards vertical force to the ball equivalent to the “D” value. Where the positive mechanical engagement arrangement retains the ball unit by means of a transverse horizontal design, the static test shall be to apply a force in this direction equivalent to 0,25 D. There shall not be any failure of the positive mechanical engagement device or any distortion likely to have an adverse effect on its function. 3.1.8. The attachment points for the secondary coupling referred to in annex 5, paragraph 1.5 shall withstand a horizontal static force equivalent to 2D with a maximum of 15 kN. Where there is a separate attachment point for a breakaway cable this shall withstand a horizontal static force equivalent to D. 3.2. Coupling heads 3.2.1. The basic test is an endurance test using an alternating test force followed by a static test (lifting test) on the same test sample. 3.2.2. The dynamic test shall be performed with a Class A coupling ball of appropriate strength. On the test rig the coupling ball and coupling head shall be arranged as instructed by the manufacturer and orientated in a way corresponding to the relative positions in normal use. There should be no possibility of extra forces in addition to the test force acting on the specimen. The test force shall be applied along a line passing through the centre of the ball and inclined downwards to the rear at 15o (see Figure 23). An endurance test must be performed on a test specimen with the following test force: Fhs res w = ±0,6 D Where the maximum permissible static vertical mass, S, exceeds 120 D, then the angle of test shall be increased to 20o. Figure 23 Dynamic test Text von Bild Fhs res 15° Fhs res 3.2.3. A static separation test shall also be performed. The coupling ball used for the test shall have a diameter of 49,00 to 49,13 mm in order to represent a worn coupling ball. The separation force, Fa, shall be applied perpendicular to both the transverse and longitudinal centre line axes of the coupling head and shall be increased smoothly and quickly to a value of: Fa = g(C+ S/1 000)kN and be held for 10 seconds. The coupling head shall not separate from the ball nor shall any component of the coupling head exhibit any permanent distortion which could have an adverse effect on its functional capability. 3.3. Drawbar couplings and drawbeams 3.3.1. An endurance test shall be performed on a test sample. The coupling device shall be equipped with all the fixings needed to attach it to the vehicle. Any intermediate devices fitted between the drawbar couplings and the vehicle frame (i.e. drawbeams) shall be tested with the same forces as the coupling. When testing drawbeams intended for standard drawbar couplings, the vertical load shall be applied at a longitudinal distance from the vertical plane of the fixing points that is equal to the position of the corresponding standard coupling. 3.3.2. Drawbar couplings for hinged drawbars (S=0) The dynamic test shall be performed with a horizontal alternating force of Fhw = ±0,6 D acting in a line parallel to the ground and in the longitudinal median plane of the towing vehicle passing through the centre of the coupling pin. 3.3.3. Drawbar couplings for use with centre‐axle trailers (S>0). 3.3.3.1. Centre axle trailer masses up to and including 3,5 tonnes: Drawbar couplings for use with centre axle trailers up to and including a mass of 3,5 tonnes shall be tested in the same way as coupling balls and towing brackets described in 3.1 of this annex. 3.3.3.2. Centre axle trailer masses exceeding 3,5 tonnes: The test forces are applied to the specimen in both horizontal and vertical directions in an asynchronous endurance test. The horizontal line of action shall be equivalent to being parallel to the ground and along the longitudinal median plane of the towing vehicle and pass through the centre of the coupling pin. The vertical line of action shall be perpendicular to the horizontal line of action and shall act along the longitudinal centre line of the coupling pin. The fixing arrangements for the drawbar coupling and the drawbar eye on the test rig shall be those intended for its attachment to the vehicle in accordance with the manufacturer's fitting instructions. The following test forces shall be applied: Table 14 Test forces Test Force Mean value (kN) Amplitude (kN) Horizontal Force 0 ±0,6 Dc (see note) Vertical Force S x g/1 000 ±0,6 V (see note) Note: In the case of Class T dedicated drawbar couplings these values shall be reduced to ±0,5 Dc and ±0,5 V. The vertical and the horizontal components shall be sinusoidal in shape and shall be applied asynchronously, where the difference of their frequencies shall be between 1 per cent and 3 per cent. 3.3.4. Static test on coupling pin locking device With drawbar couplings it is also necessary to test the closure and any locking devices by means of a static force of 0,25 D acting in the direction of opening. The test shall not cause the closure to open and it shall not cause any damage. A test force of 0,1 D is sufficient in the case of cylindrical coupling pins. 3.4. Drawbar eyes 3.4.1. Drawbar eyes shall be subjected to the same dynamic testing as drawbar couplings. Drawbar eyes used solely for trailers having hinged drawbars allowing free vertical movement shall be subjected to an alternating force as described in paragraph 3.3.2. Drawbar eyes also intended for use on centre axle trailers shall be tested in the same way as ball coupling heads (paragraph 3.2) for trailer masses C up to and including 3,5 tonnes and in the same way as drawbar couplings (paragraph 3.3.3.2.) for centre axle trailers with a mass, C, exceeding 3,5 tonnes. 3.4.2. Toroidal eyes of Class L shall be tested in the same manner as standard drawbar eyes. 3.4.3. The testing of drawbar eyes shall be conducted in such a manner that the alternating force also acts on the parts used for attaching the drawbar eye to the drawbar. All flexible intermediate components shall be clamped. 3.5. Hook type couplings 3.5.1. Class K hook type couplings shall satisfy the dynamic test given in paragraph 3.5.2 of this annex. 3.5.2. Dynamic test: 3.5.2.1. The dynamic test shall be a pulsating test using a Class L toroidal eye and with the coupling mounted as it would be on a vehicle and with all of the necessary parts for vehicle installation. However, any flexible components may be neutralised with the agreement of the type approval authority or technical service; 3.5.2.2. For hook type couplings intended for use with hinged drawbar trailers, where the imposed vertical load on the coupling, S, is zero, the test force shall be applied in a horizontal direction simulating a tensile force on the hook and varying between 0,05 D and 1,00 D; 3.5.2.3. For hook type couplings intended for use with centre axle trailers the test force shall represent the resultant of the horizontal and vertical forces on the coupling and shall be applied along an angle, -α, that is, from top front to bottom rear (see Figure 21), and equivalent to the calculated angle of the resultant between the horizontal and vertical forces on the coupling. The force, Fhs res shall be calculated as: Fhs res = sq . rt(Fh 2 + Fs 2) , where Fh = Dc and Fs = (9,81S)/1 000 + 0,8V 3.5.2.4. The applied force shall vary between and . 0,05Fhs res 1,00Fhs res 3.5.3. Static test on coupling locking device With hook type couplings it is also necessary to test the closure and any locking devices by means of a static force of 0,25 D acting in the direction of opening. The test shall not cause the closure to open and it shall not cause any damage. 3.6. Drawbars 3.6.1. Drawbars shall be tested in the same way as drawbar eyes (see paragraph 3.4.). The type approval authority or technical service may waive an endurance test if the simple design of a component makes a theoretical check of its strength possible. The design forces for the theoretical verification of the drawbar of centre axle trailers with a mass, C, of up to and including 3,5 tonnes shall be taken from ISO 7641/1: 1983. The design forces for the theoretical verification of drawbars for centre axle trailers having a mass, C, over 3,5 tonnes shall be calculated as follows: Fsp = (g × S/1 000) + V where the force amplitude V is that given in paragraph 2.11.4 of this Regulation. The permissible stresses based on the design masses for trailers having a total mass, C, over 3,5 tonnes shall be in accordance with paragraph 5.3 of ISO 7641/1: 1983. For bent drawbars (e.g. swan neck) and for the drawbars of full trailers, the horizontal force component Fhp = 1,0 × D shall be taken into consideration. 3.6.2. For drawbars for full trailers with free movement in the vertical plane, in addition to the endurance test or theoretical verification of strength, the resistance to buckling shall be verified either by a theoretical calculation with a design force of 3,0 × D or by a buckling test with a force of 3,0 × D. The permissible stresses in the case of calculation shall be in accordance with paragraph 5.3 of ISO 7641/1: 1983. 3.6.3. In the case of steered axles, the resistance to bending shall be verified by theoretical calculations or by a bending test. A horizontal, lateral static force shall be applied in the centre of the coupling point. The magnitude of this force shall be chosen so that a moment of 0,6 × Av × g (kNm) is exerted about the front axle centre. The permissible stresses shall be in accordance with paragraph 5.3 of ISO 7641/1: 1983. However, in the case where the steered axles form a twin, tandem, axle front carriage (steered bogie) the moment shall be increased to 0,95 × Av × g (kNm) 3.7. Fifth wheel couplings 3.7.1. The basic strength tests are a dynamic test and a static test (lifting test). Fifth wheel couplings intended for the positive steering of semitrailers shall be subject to an additional static test (bending test). For the purpose of the tests the fifth wheel coupling shall be equipped with all the fixings needed to attach it to the vehicle. The method of mounting shall be identical to that employed on the vehicle itself. It is not permissible to use a calculation method as an alternative to physical testing. 3.7.2. Static tests 3.7.2.1. Standard fifth wheel couplings designed for a steering wedge or similar device for the positive steering of semitrailers (see paragraph 2.7 of this Regulation) shall be tested for adequate strength by means of a static bending test within the working range of the steering device with the simultaneous application of fifth wheel load. The maximum permitted imposed vertical load, U, for the fifth wheel shall be applied vertically to the coupling in its operating position by means of a rigid plate of sufficient size to cover the coupling completely. The resultant of the applied load shall pass through the centre of the horizontal joint of the fifth wheel coupling. Simultaneously, a horizontal lateral force, representing the force needed for positive steering of the semitrailer, shall be applied to the flanks of the guide for the coupling pin. The magnitude of this force and the direction in which it acts shall be chosen so that a moment of 0,75m × D is exerted about the centre of the coupling pin by means of a force acting on a lever arm 0,5 m ± 0,1 m long. Permanent, plastic deformation up to 0,5 per cent of all nominal dimensions is permitted. There shall not be any cracking. 3.7.2.2. A static lifting test shall be performed on all fifth wheel couplings. Up to a lifting force of Fa = g.U there shall not be any major permanent bending of the coupling plate over more than 0,2 per cent of its width. In the case of Class G50 standard fifth wheel couplings and comparable couplings for the same coupling pin diameter, there shall not be any separation of the coupling pin from the coupling with a lifting force of Fa = g × 2,5 U. In the case of non‐standard couplings using a pin diameter greater than 50 mm, for example 90 mm pin diameter couplings, the lifting force shall be: Fa = g × 1,6 U with a minimum value of 500 kN. The force shall be applied by means of a lever bearing on the coupling plate at one end and being raised at the other end at a d