Europäische Union

2005/614/EG: Beschluss des Rates vom 18. Juli 2005 über den Beitritt der Gemeinschaft zu zwei Regelungen der Wirtschaftskommission der Vereinten Nationen für Europa: Regelung Nr. 94 über Bedingungen für die Genehmigung der Fahrzeuge hinsichtlich des Schutzes der Insassen bei einem Frontaufprall und Regelung Nr. 95 über Bedingungen für die Genehmigung der Fahrzeuge hinsichtlich des Schutzes der Insassen bei einem Seitenaufprall (Text von Bedeutung für den EWR)

Amtliche Ursprungsfassung

Quellenkennung: 32005D0614. Spätere Änderungen sind nicht automatisch in dieser Fassung enthalten.

Originaldateien und Anlagen

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

.1. The fitting on the trolley must be according to Figure 8. The fitting will use six M8 bolts, and nothing shall be larger than the dimensions of the barrier in front of the wheels of the trolley. Appropriate spacers must be used between the lower back plate flange and the trolley face to avoid bowing of the back plate when the attachment bolts are tightened. 3. VENTILATION SYSTEM 3.1. The interface between the trolley and the ventilation system should be solid, rigid and flat. The ventilation device is part of the trolley and not of the impactor as supplied by the manufacturer. Geometrical characteristics of the ventilation device shall be according to Figure 9. 3.2. Ventilation device mounting procedure. 3.2.1. Mount the ventilation device to the front plate of the trolley; 3.2.2. Ensure that a 0,5 mm thick gauge cannot be inserted between the ventilation device and the trolley face at any point. If there is a gap greater than 0,5 mm, the ventilation frame will need to be replaced or adjusted to fit without a gap of > 0,5 mm. 3.2.3. Dismount the ventilation device from the front of the trolley; 3.2.4. Fix a 1,0 mm thick layer of cork to the front face of the trolley; 3.2.5. Re-mount the ventilation device to the front of the trolley and tighten to exclude air gaps. 4. CONFORMITY OF PRODUCTION The conformity of production procedures shall comply with those set out in the Agreement, Appendix 2 (E/ECE/324-E/ECE/TRANS/505/Rev.2), with the following requirements: The manufacturer shall be responsible for the conformity of production procedures and for that purpose must in particular: 4.1.1. ensure the existence of effective procedures so that the quality of the products can be inspected; 4.1.2. have access to the testing equipment needed to inspect the conformity of each product; 4.1.3. ensure that the test results are recorded and that the documents remain available for a time period of 10 years after the tests; 4.1.4. demonstrate that the samples tested are a reliable measure of the performance of the batch (examples of sampling methods according to batch production are given below); 4.1.5. analyse results of tests in order to verify and ensure the stability of the barrier characteristics, making allowance for variations of an industrial production, such as temperature, raw materials quality, time of immersion in chemical, chemical concentration, neutralisation etc, and the control of the processed material in order to remove any residue from the processing; 4.1.6. ensure that any set of samples or test pieces giving evidence of non-conformity gives rise to a further sampling and test. All the necessary steps must be taken to restore conformity of the corresponding production; 4.2. The manufacturer’s level of certification must be at least ISO 9002 standard; 4.3. Minimum conditions for the control of production: the holder of an agreement will ensure the control of conformity following the methods hereunder described; 4.4. Examples of sampling according to batch 4.4.1. If several examples of one block type are constructed from one original block of aluminium honeycomb and are all treated in the same treatment bath (parallel production), one of these examples could be chosen as the sample, provided care is taken to ensure that the treatment is evenly applied to all blocks. If not, it may be necessary to select more than one sample. 4.4.2. If a limited number of similar blocks (say three to 20) are treated in the same bath (serial production), then the first and last block treated in a batch, all of which are constructed from the same original block of aluminium honeycomb, should be taken as representative samples. If the first sample complies with the requirements but the last does not, it may be necessary to take further samples from earlier in the production until a sample that does comply is found. Only the blocks between these samples should be considered to be approved. 4.4.3. Once experience is gained with the consistency of production control, it may be possible to combine both sampling approaches, so that more than one groups of parallel production can be considered to be a batch provided samples from the first and last production groups comply. 5. STATIC TESTS 5.1. One or more samples (according to the batch method) taken from each batch of processed honeycomb core shall be tested, according to the following test procedure: 5.2. The sample size of the aluminium honeycomb for static tests shall be the size of a normal block of the impactor, that is to say 250 mm x 500 mm x 440 mm for top row and 250 mm x 500 mm x 500 mm for the bottom row. 5.3. The samples should be compressed between two parallel loading plates which are at least 20 mm larger that the block cross section. 5.4. The compression speed shall be 100 millimetres per minute, with a tolerance of 5 %. 5.5. The data acquisition for static compression shall be sampled at a minimum of 5 Hz. 5.6. The static test shall be continued until the block compression is at least 300 mm for blocks 4 to 6 and 350 mm for blocks 1 to 3. 6. DYNAMIC TESTS For every 100 barrier faces produced, the manufacturer shall make one dynamic test against a dynamometric wall supported by a fixed rigid barrier, according to the method described below. 6.1. Installation 6.1.1. Testing ground 6.1.1.1. The test area shall be large enough to accommodate the run-up-track of the mobile deformable barrier, the rigid barrier and the technical equipment necessary for the test. The last part of the track, for at least five metres before the rigid barrier, shall be horizontal, flat and smooth. 6.1.2. Fixed rigid barrier and dynamometric wall. 6.1.2.1. The rigid wall shall consist of a block of reinforced concrete not less than three metres wide and not less than 1,5 metres high. The thickness of the rigid wall shall be such that it weighs at least 70 tonnes. 6.1.2.2. The front face shall be vertical, perpendicular to the axis of the run-up-tack and equipped with six load cell plates, each capable of measuring the total load on the appropriate block of the mobile deformable barrier impactor at the moment of impact. The load cell impact plate area centres shall align with those of the six impact zones of the mobile deformable barrier face. Their edges shall clear adjacent areas by 20 mm such that, within the tolerance of impact alignment of the MDB, the impact zones will not contact the adjacent impact plate areas. Cell mounting and plate surfaces shall be in accordance with the requirements set out in the Annex to standard ISO 6487:1987. 6.1.2.3. Surface protection, comprising a plywood face (thickness: 12 ± 1 mm), is added to each load cell plate such that it shall not degrade the transducer responses. 6.1.2.4. The rigid wall shall be either anchored in the ground or placed on the ground with, if necessary, additional arresting devices to limit its deflection. A rigid wall (to which the load cells are attached) having different characteristics but giving results that are at least equally conclusive may be used. 6.2. Propulsion of the mobile deformable barrier At the moment of impact the mobile deformable barrier shall no longer be subject to the action of any additional steering or propelling device. It shall reach the obstacle on a course perpendicular to the front surface of the dynamometric wall. Impact alignment shall be accurate to within 10 mm. 6.3. Measuring instruments 6.3.1. Speed The impact speed shall be 35 ± 0,5 km/h the instrument used to record the speed on impact shall be accurate to within 0,1 %. 6.3.2. Loads Measuring instruments shall meet the specifications set forth in ISO 6487:1987 CFC for all blocks : 60 Hz CAC for blocks 1 and 3 : 200 kN CAC for blocks 4,5 and 6 : 100 kN CAC for block 2 : 200 kN 6.3.3. Acceleration 6.3.3.1. The acceleration in the longitudinal direction shall be measured at three separate positions on the trolley, one centrally and one at each side, at places not subject to bending. 6.3.3.2. The central accelerometer shall be located within 500 mm of the location of the centre of gravity of the MDB and shall lie in a vertical longitudinal plane which is within ± 10 mm of the centre of gravity of the MDB. 6.3.3.3. The side accelerometers shall be at the same height as each other ± 10 mm and at the same distance from the front surface of the MDB ± 20 mm 6.3.3.4. The instrumentation shall comply with ISO 6487:1987 with the following specifications: CFC 1,000 Hz (before integration) CAC 50 g 6.4. General specifications of barrier 6.4.1. The individual characteristics of each barrier shall comply with paragraph 1 of this Annex and shall be recorded. 6.5. General specifications of the impactor 6.5.1. The suitability of an impactor as regards the dynamic test requirements shall be confirmed when the outputs from the six load cell plates each produce signals complying with the requirements indicated in this Annex. 6.5.2. Impactors shall carry consecutive serial numbers which are stamped, etched or otherwise permanently attached, from which the batches for the individual blocks and the date of manufacture can be established. 6.6. Data processing procedure 6.6.1. Raw data: At time T = T0, all offsets should be removed from the data. The method by which offsets are removed shall be recorded in the test report. 6.6.2. Filtering 6.6.2.1. The raw data will be filtered prior to processing/calculations. 6.6.2.2. Accelerometer data for integration will be filtered to CFC 180, ISO 6487:1987. 6.6.2.3. Accelerometer data for impulse calculations will be filtered to CFC 60, ISO 6487:1987. 6.6.2.4. Load cell data will be filtered to CFC 60, ISO 6487:1987. 6.6.3. Calculation of MDB face deflection 6.6.3.1. Accelerometer data from all three accelerometers individually (after filtering at CFC 180), will be integrated twice to obtain deflection of the barrier deformable element. The initial conditions for deflection are: 6.6.3.2.1. velocity = impact velocity (from speed measuring device). 6.6.3.2.2. deflection = 0 6.6.3.3. The deflection at the left hand side, mid-line and right hand side of the mobile deformable barrier will be plotted with respect to time. 6.6.3.4. The maximum deflection calculated from each of the three accelerometers should be within 10 mm. If it is not the case, then the outlier should be removed and difference between the deflection calculated from the remaining two accelerometers checked to ensure that it is within 10 mm. 6.6.3.5. If the deflections as measured by the left hand side, right hand side and mid-line accelerometers are within 10 mm, then the mean acceleration of the three accelerometers should be used to calculate the deflection of the barrier face. 6.6.3.6. If the deflection from only two accelerometers meets the 10 mm requirement, then the mean acceleration from these two accelerometers should be used to calculate the deflection for the barrier face. 6.6.3.7. If the deflections calculated from all three accelerometers (left hand side, right hand side and mid-line) are not within the 10 mm requirement, then the raw data should be reviewed to determine the causes of such large variation. In this case the individual test house will determine which accelerometer data should be used to determine mobile deformable barrier deflection or whether none of the accelerometer readings can be used, in which case, the certification test must be repeated. A full explanation should be given in the test report. 6.6.3.8. The mean deflection-time data will be combined with the load cell wall force-time data to generate the force deflection result for each block. 6.6.4. Calculation of energy The absorbed energy for each block and for the whole MDB face should be calculated up to the point of peak deflection of the barrier. Text von Bild En = t1∫t0 Fn . dsmean where: t0 is the time of first contact t1 is the time where the trolley comes to rest, i.e. where u = 0. s is the deflection of the trolley deformable element calculated according to paragraph 6.6.3. 6.6.5. Verification of dynamic force data 6.6.5.1. Compare the total impulse, I, calculated from the integration of the total force over the period of contact, with the momentum change over that period (M*V). 6.6.5.2. Compare the total energy change to the change in kinetic energy of the MDB, given by: Text von Bild EK = 1 2 MV 2 i where Vi is the impact velocity and M the whole mass of the MDB If the momentum change (M*V) is not equal to the total impulse (I) ± 5 %, or if the total energy absorbed (E En) is not equal to the kinetic energy, EK ± 5 %, then the test data must be examined to determine the cause of this error. Design of impactor (22) Design of impactor (1) 500 ± 5 500 ± 5 500 ± 5 250 ± 3 Zone 5 Zone 4 Zone 6 500 ± 2.5 250 ± 3 Zone 1 Zone 2 Zone 3 1500 ± 2.5 60 ± 2 250 ± 3 Level B 250 ± 3 500 ± 2 mm (including the front plate but not the back plate) Impactor Top Direction L Direction W Expansion direction of the Aluminium honeycomb 19mm ± 1.9mm 1500 ± 1mm 520 ± 1mm > 500mm Ventilation device Cork gasket ≥ 53 mm Front plate of trolley 514 ± 1 mm Side View Spacer 12 mm ± 0.2 12 mm ± 0.2 ∅ 8 mm ± 0.2 150 ± 1 mm 600 ± 1 mm 600 ± 1 mm Barrier side 28 ± 1 mm ≥ 3 mm Trolley side ≥ 17 mm R = 5 mm Top and bottom back plate flanges Note: The attachment holes in the bottom flange may be opened to slots, as shown below, for ease of attachment provided sufficient grip can be developed to avoid detachment during the whole impact test. 28 ± 1mm 150 ± 1mm 600 ± 1mm 600 ± 1mm Barrier side R = 5mm Trolley side Bottom The ventilation device is a structure made of a plate that is 5 mm thick and 20 mm wide. Only the vertical plates are perforated with nine 8 mm holes in order to let air circulate horizontally. 1500 ± 2.5 mm 500 ± 2.5 mm 250 mm 250 mm 250 mm 250 mm 250 mm 50 mm between 2 plates Thickness: 20 mm Plates (50*50*4 mm) to fix the device on trolley by M8 screws. Front View Section Lateral view of vertical struts 5 mm ∅ 8 mm Side View Figure 9 Appendix 1 Force deflection curves for static tests Blocks 1 and 3 Figure 1a Block 2 Figure 1b Block 4 Figure 1c Blocks 5 and 6 Figure 1d Appendix 2 Force deflection curves for dynamic tests Blocks 1 and 3 Figure 2a Block 2 Figure 2b Block 4 Figure 2c Blocks 5 and 6 Figure 2d Blocks total Figure 2e ANNEX 6 Technical description of the side impact dummy 1. GENERAL 1.1. The dimensions and masses of the side impact dummy represent a 50th percentile adult male, without lower arms. 1.2. The side impact dummy consists of a metal and plastic skeleton covered by flesh-simulating rubber, plastic and foam. 1.3. The side impact dummy prescribed in this Regulation, including the instrumentation and calibration, is described in technical drawings and a user’s manual (23). 2. CONSTRUCTION 2.1. For an overview of the side impact dummy see Figure 1 and Table 1 of this Annex. 2.2. Head 2.2.1. The head is shown as part No 1 in Figure 1 of this Annex. 2.2.2. The head consists of an aluminium shell covered by a pliable vinyl skin. The interior of the shell is a cavity accommodating triaxial accelerometers and ballast. 2.3. Neck 2.3.1. The neck is shown as part No 2 in Figure 1 of this Annex. 2.3.2. The neck consists of a head/neck interface piece, a neck/thorax interface piece and a central section that links the two interfaces to one another. 2.3.3. The head/neck interface piece (part No 2a) and the neck/thorax interface piece (part No 2c) both consist of two aluminium disks linked together by means of a half spherical screw and eight rubber buffers. 2.3.4. The cylindrical central section (part No 2b) is made of rubber. 2.3.5. The neck is mounted on the neck-bracket, shown as part No 3 in Figure 1 of this Annex. 2.3.6. The angle between the two faces of the neck-bracket is 25°. Because the shoulder block is inclined 5° backwards, the resulting angle between the neck and torso is 20°. 2.4. Shoulder 2.4.1. The shoulder is shown as part No 4 in Figure 1 of this Annex. 2.4.2. The shoulder consists of a shoulder block, two clavicles and a shoulder cap. 2.4.3. The shoulder block (part No 4a) consists of an aluminium spacer block, an aluminium plate on top and an aluminium plate on the bottom of the spacer block. 2.4.4. The clavicles (part No 4b) are made of polypropylene. The clavicles are held back in their neutral position by two elastic cords (part No 4c) which are clamped to the rear of the shoulder block. The outer edge of both clavicles accommodates a design allowing for standard arm positions. 2.4.5. The shoulder cap (part No 4d) is made of low-density polyurethane foam and is attached to the shoulder block. 2.5. Thorax 2.5.1. The thorax is shown as part No 5 in Figure l of this Annex. 2.5.2. The thorax consists of a rigid thoracic spine box and three identical rib modules. 2.5.3. The thoracic spine box (part No 5a) is made of steel. On the rear surface a lead-filled plastic back plate is mounted (part No 5b). 2.5.4. The top surface of the thoracic spine box is inclined 5° backwards. 2.5.5. A rib module (part No 5c) consists of a steel rib covered by a flesh-simulating polyurethane foam (part No 5d), a piston-cylinder assembly (part No 5e) linking the rib and spine box together, a hydraulic damper (part No 5f) and a stiff damper spring (part No 5g). 2.5.6. In the piston-cylinder assembly is a tuning spring (part No 5h). 2.5.7. A displacement transducer (part No 5i) can be mounted on the front face of the cylinder and connected to the inside of the rib. 2.6. Arms 2.6.1. The arms are shown as part No 6 in Figure 1 of this Annex. 2.6.2. The arms have a plastic skeleton covered by a polyurethane ‘flesh’ and a PVC skin. 2.6.3. The shoulder/arm joint allows for discrete arm positions at 0°, 40° and 90° to the torso line. 2.6.4. The shoulder/arm joint allows for a flexion/extension rotation only. 2.7. Lumbar spine 2.7.1. The lumbar spine is shown as part No 7 in Figure 1 of this Annex. 2.7.2. The lumbar spine consists of a solid rubber cylinder with two steel interface plates at each end, and a steel cable inside the cylinder. 2.8. Abdomen 2.8.1. The abdomen is shown as part No 8 in Figure 1 of this Annex. 2.8.2. The abdomen consists of a metal casting and a polyurethane foam covering. 2.8.3. The central part of the abdomen is a metal casting (part No 8A). A cover plate is mounted on top of the casting. 2.8.4. The covering (part No 8b) is made of polyurethane foam. A curved slab of rubber filled with lead-pellets is integrated in the foam covering at both sides. 2.8.5. Between the foam covering and the rigid casting at each side of the abdomen, either three force transducers (part No 8c) or three non-measuring ‘dummy’ units can be mounted. 2.9. Pelvis 2.9.1. The pelvis is shown as part No 9 in Figure 1 of this Annex. 2.9.2. The pelvis consists of a sacrum block, two iliac wings, two hip joints and a foam covering. 2.9.3. The sacrum (part No 9a) consists of a lead-filled aluminium block and an aluminium plate mounted on top of this block. 2.9.4. The iliac wings (part No 9b) are made of polyurethane. 2.9.5. The hip joints (part No 9c) are made of steel. They consist of an upper femur block and a ball joint connected to an axle passing through the dummy’s H-point. 2.9.6. The flesh system (part No 9d) is made of a PVC skin filled with polyurethane foam. At the H-point location the skin is replaced by a large open-cell polyurethane foam cylinder (part No 9e), attached to a steel plate fixed on the iliac wing by an axle going through the ball joint. 2.9.7. The iliac wings are linked together at the pubic symphysis by a force transducer (part No 9f) or a ‘dummy’ transducer. 2.10. Legs 2.10.1. The legs are shown as part No 10 in Figure 1 of this Annex. 2.10.2. The legs consist of a metal skeleton covered by a flesh-simulating polyurethane foam and a plastic skin. 2.10.3. The knee and ankle joint allow for a flexion/extension rotation only. 2.11. Suit 2.11.1. The suit is shown as part No 11 in Figure 1 of this Annex. 2.11.2. The suit is made of rubber and covers the shoulders, thorax, upper part of the arms, the abdomen and lumbar spine, the upper part of the pelvis. Figure 1 Construction of side impact dummy Text von Bild (F = front view, S = side view, T = top view) Table 1 Side impact dummy components Part No Description Number 1 Head 1 2 Neck 1 2a Head/neck interface 1 2b Central section 1 2c Neck/thorax interface 1 3 Neck-bracket 1 4 Shoulder 1 4a Shoulder block 1 4b Clavicles 2 4c Elastic cord 2 4d Shoulder cap 1 5 Thorax 1 5a Thoracic spine 1 5b Back plate 1 5c Rib module 3 5d Rib covered with flesh 3 5e Piston-cylinder assembly 3 5f Damper 3 5g Damper spring 3 5h Tuning spring 3 5i Displacement transducer 3 6 Arm 2 7 Lumbar spine 1 8 Abdomen 1 8a Central casting 1 8b Flesh covering 1 8c Force transducer 3 9 Pelvis 1 9a Sacrum block 1 9b Iliac wing 2 9c Hip joint 2 9d Flesh covering 1 9e H-point foam block 2 9f Force transducer 1 10 Leg 2 11 Suit 1 3. ASSEMBLY OF THE DUMMY 3.1. Head-neck 3.1.1. The required torque on the half spherical screws for assembly of the neck is 10 Nm. 3.1.2. The head is mounted to the head-neck interface plate of the neck by three screws. 3.1.3. The neck-thorax interface plate of the neck is mounted to the neck-bracket by four screws. 3.2. Neck-shoulder-thorax 3.2.1. The neck-bracket is mounted to the shoulder block by four screws. 3.2.2. The shoulder-block is mounted to the top-surface of the thoracic spine box by three screws. 3.3. Shoulder-arm 3.3.1. The arms may be mounted to the shoulder clavicles and adjusted by means of a screw and a bearing. The required torque to hold the arm in the defined standard position is 0,6 Nm. 3.4. Thorax-lumbar spine-abdomen 3.4.1. A lumbar spine adaptor is mounted by two screws to the lower part of the thoracic spine. 3.4.2. The lumbar spine adaptor is mounted to the top of the lumbar spine by two screws. 3.4.3. The top flange of the central abdominal casting is clamped between the lumbar spine adaptor and the lumbar spine. 3.5. Lumbar spine-pelvis-legs 3.5.1. The lumbar spine is mounted to the lumbar spine bottom plate by three screws. 3.5.2. The lumbar spine bottom plate is mounted to the sacrum block of the pelvis by three screws. 3.5.3. The legs are mounted to the upper femur - hip joint of the pelvis by a screw. 3.5.4. The legs may be assembled and adjusted by means of hinge joints in the knees and ankles. 4. MAIN CHARACTERISTICS 4.1. Mass 4.1.2. The masses of the main dumm