tno homologations b.v. - coletto · • tno is the netherlands’ organisation for applied research...

TNO Homologations B.V.

Frank Brouwers

Hong Kong January 11 2011Seminar on "Safety Requirements of Infants and Children Products"2

• TNO Automotive in a nutshell

• TNO Homologations B.V.

• ECE44 a summary

• CoP procedure

• New Universal Isofix regulation



TNO / Business Unit Automotive forward thinking beyond traditional borders

• TNO is the Netherlands’ Organisation for Applied Research

• Over 75 years of experience• Independent R&D organisation• 4,500 employees world-wide• HQ in Delft, the Netherlands• Annual turnover approx. 550 M€


Market Portals of TNO Science & Industry


Business unit Automotive in a nutshell

• 4 departments• Over 35 years of automotive

experience• 170 employees• > 65% master of PHD• Located in Helmond• International market• Annual turnover close to 30M€


Predominantly International Customers

1

23


Fields of expertise Business Unit Automotive

BU Automotive

Integrated Safety

Crash Testing/TTAI Homologations BV

Powertrains


TTAI Crash Testing


TNO VeHIL

TNO Offices

TNO Powertrain

testing




• ECE44 a summary

• CoP procedure




TNO Homologations B.V. (general)

Activities

• Approval testing• Over 60 (inter-)national standards, regulations and

directives

• Conformity-of-Production (CoP) testing• according to various homologation directives • as part of the quality system of manufacturers


Facts and figures

• About TNO Homologations B.V.• Process in house• Global accreditations

• ISO 17020 and 17025• ISO 9000/2001• RDW - 99050003 00

• Over 30 years of experience• 8000 samples a year• 25 employees• 4.5 million Euro annual turnover


Position of TNO Homologations B.V.

Clients

Require- ments

Certifying bodies

Testing facilities



Main subjects

• Car safety belts• Child restraint systems• Exhaust gas emissions• Helmets• Anti-theft systems• Alarm systems


Child restraint systems

• Regulations:• ECE-44

• Accreditations:• Europe (UNECE)• Brazil ABNT NBR 14400

• Facilities:• Restraint system laboratory• 1 crash simulator• Durability, ageing, etc.


60 meter crash simulator with ECE-44 sled


Restraint laboratory

Hong Kong January 11 2011Seminar on "Safety Requirements of Infants and Children Products"17 TNO Automotive Helmond17

Buckle release equipment

Hong Kong January 11 2011Seminar on "Safety Requirements of Infants and Children Products"18 TNO Automotive Helmond18

Buckle endurance equipment




• ECE44 a summary

• CoP procedure


TNO Homologations BV


ECE 44-04 Regulation a summary

• 1958 Agreement on ECE type approvalsAgreement concerning the adoption of uniform conditions of approval and reciprocal recognition of approval for motor vehicle equipment and parts, done at Geneva on 20 March 1958.

• UNECE Working party of passive safety (GRSP)The Working Party on Passive Safety is the subsidiary body of the World Forum for Harmonization of Vehicle Regulations (WP.29) that prepares regulatory proposals on passive safety to WP.29.

• UNECE Vehicle regulation126 regulations for automotive (related) components.

• R44 Child restraint systems• R14 Safety belt anchorages and ISOFIX anchorage systems• R16 Installation safety belts, restraint systems safety belts, restraint

systems installation Child restraint / ISOFIX systems


UNECE Vehicle regulation on www.unece.org


ECE 44-04 Regulation contents

• Mass Groups• Anchorage systems• Categories• Static tests• Dynamic tests• Information document• CoP



Mass Groups

Group Weight Dummy

0 m < 10 kg P0 + P3/4

0+ m < 13 kg P0 + P1,5

I 9 < m > 18 kg P3/4 + P3

II 15 < m > 25 kg P3 + P6

III 22 < m > 36 kg P6 + P10



Anchorage systems

• Three point belt (ABC)• ISOFIX (only group 0,0+,I)

• top tether• support leg

Categories:• Universal, Semi universal, Restricted, Specific Vehicle• Integral and non Integral



Static tests• Temperature test• Endurance test central adjuster (5000x)• Endurance test buckle (5000x)• Buckle release force unloaded• Buckle release force loaded• Static strength test buckle• Strength test webbing• Micro slip central adjuster• Adjusting device test• Lock-off test • Overturning or roll over test• Energy absorption test• Corrosion and dust resistance test



Dynamic tests

Group Impact Facing

0 Frontal - Rear Rear - Perp.

0+ Frontal - Rear Rear

I Frontal – (Rear) Forward (Rear)

II Frontal Forward

III Frontal Forward



Dynamic tests

+ M POINT001 CR LHS (1)

+ M POINT009 TOPHR RHS (15)

+ M POINT008 BOTTOM RHS (13)

+ M POINT010 BAR RHS (11)

+ M POINT003 BOTTOM LHS (11)



Information document

• Warning labels• User manual• Drawings• Packaging at the point of sale• Declarations of flammability and toxicity




• ECE44 a summary

• CoP procedure




Conformity of Production procedure

A Child Restraint System is a safety product!


• Type approval process

• CoP Documents

• Compliance statement Approval Authority (RDW)


Type Approval Process

Technical Service (TNO)RDW

Manufacturer

- ACCREDITATION- INITIAL ASSESSMENT- ASSESSMENT APPLICATION

- PERFORM TEST[S]

- ISSUE TYPE APPROVAL

- PREPARATION DOCUMENTS- INTERMEDIAIR

- ASSESSMENT CONFORMITY OF PRODUCTION

- COP INFORMATION

- SAMPLE- INFORMATION DOCUMENT

- FULFILLMENT REQUIREMENTS



CoP Documents Initial Assessment

• CoP Surveillance• ISO 9001 Certificate• ISO Quality Manual• CoP Control Plan• CoP Administration

Compliance statement Approval Authority (RDW)


Conformity of Production (CoP) tests

Dynamic tests• Batch control

• 2 samples• Batch must not exceed 5000 pieces

• Continuous control• 1 sample• Sample taken from every 5000 manufactured

Yearly test• Test for strength of straps after conditioning• Test for strength of straps after abrasion• Microslip test• Energy absorption• Dynamic test• Temperature test





• ECE44 a summary

• CoP procedure

• New Universal ISOFIX regulation



• Size definitions

• Q-dummies

• Geometric characteristics

• Dynamic tests front and rear

• Dynamic test lateral

• Head containment

Size Universal ISOFIX with support leg


• “Size” (Integral Universal Isofix child restraint systems) is a category indication for a child restraint system meaning it is for use in all Size ready vehicles, not necessarily on all vehicle positions, approved according to Regulation No.16 (to be amended) including its suitability for such a category of child restraint system.

• For children under the age of 15 months only carry-cot or rearward facing child restraint system must be used. The use of rearward facing child restraint system is authorised for any age.

• The mass of an Size child restraint system combined with the mass of the biggest child intended to use the child restraint system shall not exceed 33 kg.




Description of manikins:


Geometrical characteristics:


StatureSitting height Shoulder

height

Shoulder breadth

Hip breadth



size indication:

Selection criteria for the smallest dummy according to the minimum size indication

Minimum size indication

below 60 cm between 60 and 75 cm

between 75 and 87 cm



above 125 cm

Dummy Q0 Q1 Q1.5 Q3 Q6 Q10



size Support Legfoot dimensions:

[190mm



Dynamic tests:• Frontal impact and Rear impact

• Head Impact Criterion HIC (15)• Head acceleration 3ms• Chest acceleration 3ms• Upper neck Tension Force (for monitoring purpose only)• Upper neck Flexion Moment (for monitoring purpose only)• Head excursion horizontal (500mm forward facing and 700mm rearward

facing)• Lateral (side) impact

• Head Impact Criterion HIC (15)• Head acceleration 3ms• Upper neck Tension Force (for monitoring purpose only)• Upper neck Flexion Moment (for monitoring purpose only)• Head containment (no door contact, not over red line and not over side

wings car seat)



Lateral (side) Impact• Based on rear-impact pulse• 90 degree rotation on the ECE44 bench• Fixed door panel on the stopping block• Moving ISOFIX anchorages• Management of intrusion distance



Definition of t0 and Intrusion:• Acceleration starts at t0• Position of door at t0 according to figure below

Maximum Intrusion

50 mm

At t0

Bench Centreline

350 mm


20 m

ax

600

500

Tbd in Phase2


Door Specification



Proposal head containment:

Not containedcontainedcontained



Questions

• Changing harness position without tool or disassembly• Dimensions support leg. • Size ready cars. One seat or all seat?• Repeatability of the lateral Impact test?• Higher pulse for frontal impact?• End of fase 1 in May 2011 (only ISOFIX seats)• End of fase 2 December 2012 (ISOFIX and 3-point belt)• End of fase 3 ?? (Only 3-point belt)


TNO Homologation B.V. for you!

• Testing and Type approval• ECE44 and ABNT NBR 14400:2009 (Brazil)• Experimental pre-test• Complete approval testing program

• ECE44• ABNT NBR 14400:2009 (Brazil)

• CoP tests• Consultancy

• CoP documents• Updates current regulations• Information about new regulations

• Software (Madymo) simulation


TNO’s benefits in homologations

• Over 30 years experience• Global accreditations and acceptance of test results• TNO has been working closely with regulatory bodies to

develop the ECE regulation• TNO consults customers in understanding ECE regulations

and informs about new developments in ECE standards• Combined package of different approvals possible with one

series of tests• Clear deliverables / products• Fixed price list• Standard order form

CRS Homologation


Thank you for your attention.

For information:

Frank BrouwersProduct Manager Child Restraint Systems

TNO Homologations BVSteenovenweg 1a, 5708 HN, HELMONDP.O. Box 753, 5700 AT, HELMONDThe Netherlands

T: +31 (0)88 86 65756M: +31 (0)6 224 081 72F: +31 (0)88 86 68874

E: [email protected]: www.tno.nl

http://www.tno.nl/


Questions?

Thank you for your attention.