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Page 1/37
CONTENTS
2.1
2.2
General description of purpose .........................................................................................................................3
2.2.1
Design perimeter...........................................................................................................................................3
2.2.2
Reference nomenclature ..............................................................................................................................3
2.2.3
Outline dimensions .......................................................................................................................................4
2.2.4
Operating mode ............................................................................................................................................4
5.1
Europe impact functional requirements ...........................................................................................................6
5.1.1
Urban impact.................................................................................................................................................6
5.1.2
ECE 42........................................................................................................................................................10
5.1.3
High speed impact ......................................................................................................................................12
5.2
Europe transportability functional requirements...........................................................................................14
5.2.1
Recommendations for the design ...............................................................................................................14
5.2.2
The tow ring ................................................................................................................................................14
5.2.3
Load Case...................................................................................................................................................14
5.2.4
Homologation towing ..................................................................................................................................15
5.2.5
Sea securing ...............................................................................................................................................16
5.2.6
Lifting on a truck..........................................................................................................................................17
5.2.7
Dynamic towing...........................................................................................................................................17
5.2.8
Criteria for acceptance................................................................................................................................19
5.3
5.4
Interface requirements......................................................................................................................................21
5.5
Operational requirements.................................................................................................................................22
5.5.1
Process scenario ........................................................................................................................................22
5.5.2
Fitness for assembly ...................................................................................................................................22
5.5.3
Ergonomics and human factors ..................................................................................................................22
5.6
Constraint requirements...................................................................................................................................22
5.6.1
Weight.........................................................................................................................................................22
5.6.2
Cost.............................................................................................................................................................22
5.6.3
Deadlines ....................................................................................................................................................22
5.6.4
Quality factors .............................................................................................................................................22
5.6.5
Materials .....................................................................................................................................................23
5.6.6
Industrial standardization and regulation ....................................................................................................32
5.6.7
Interchangeability........................................................................................................................................32
5.6.8
Marking of the components ........................................................................................................................33
5.6.9
Logistics / transportability ...........................................................................................................................33
5.6.10
FTC (Functional Technical Characteristics) ...............................................................................................33
5.7
Integration and validation requirements.........................................................................................................33
5.7.1
Validation plan ............................................................................................................................................33
5.7.2
Calculation and tests Spec .........................................................................................................................34
5.8
Failsafe operation and List of the Criticality 3 and 4 DE (Dreaded Events) ................................................35
6.1
Appendix 1 Transportability .............................................................................................................................36
6.1.1
UTAC (Union Technique de l'Automobile, du Motocycle et du Cycle) homologation towing .....................36
6.1.2
Sea securing ...............................................................................................................................................36
6.1.3
Lifting on a truck..........................................................................................................................................37
6.1.4
Dynamic towing...........................................................................................................................................37
Page 2/37
1. PURPOSE
The aim of the study is to propose a system that integrates in a given volume and that meets the specifications, with a
beam/absorber length to be defined by your calculations, depending on the project constraints, particularly on the overhang and on the
position of the wall after the impact.
The delivered parts must comply with the functional technical specifications described in this document. Our standards are
available upon request to the Purchase Division.
2. SCOPE
2.1 General description of the vehicle(s)
Volume, Mix (to be sent by the Purchase Division)
Manufacturing site: integrated in CDC EC.
Page 3/37
Input data
Volume and maximum outline dimensions before impact
Interfaces (rails, caulking plates, low support fastening)
CAD definition
CATIA files to be required from the
DO (Design Office)
The system must be compatible with the assigned volume (volume and maximum outline dimensions before impact).
3. REFERENCE DOCUMENTS
Page 4/37
2000/53/EC
2003/138/EC
ECE 42
ISO 5422 "towing out of a pit"
RG00162_CEE77-389
RG00162_CEE96-64
B20 0200
4. GLOSSARY
The technical and specific terms, as well as the abbreviations and acronyms used in this document are defined in the
MANAGEMENT AND QUALITY ASSURANCE CLAUSES.
Page 5/37
5. REQUIREMENTS
5.1 Europe impact functional requirements
This section lists all the performances included in the design perimeter. All the performances are required on a temperature
range of 23 4 C and for a humidity range from 0 to 100%.
5.1.1 Urban impact
Requirement and conditions:
Functional Requirement no. 1:
Dissipate the energy upon an ALLIANZ impact
Functional Requirement no. 2:
Do not deteriorate the structure of the vehicle during the ALLIANZ impact
Test conditions
Wall leaning at 10
Speed: 16 km/h
Recovery equivalent to 40 % of the vehicle
Vehicle weight: 1225 kg
Updated vehicle weight depending on the test means
Justification:
Reparability
Data provided to the supplier:
CAD file for the assigned volume before impact.
Numerical calculus model
Performance criteria:
The complete system must dissipate at least 6500 J on a vehicle, before saturation whatever the product/process dispersions.
The saturation of the system corresponds to the moment when the system achieves its energy goal.
The system must comply with the available volume before impact and with the volume and the position of the wall upon the
maximum dynamic sinking.
The length of the non deformed system must be of maximum 135 mm (not including the thickness of the plate) on the absorber
axis at Y=507.
The residual dimension of the system at its maximum dynamic collapse must be of around 20 mm, on the absorber axis at
Y=507, so that the efficiency of the absorber reaches the 85%.
The maximum sinking must be on the absorber level; no part of the frame may penetrate along X more than the latter. The beam
must remain in front of the compressibility limit of the absorbers.
Page 6/37
Compressibility
limit
The maximum effort must be of 75 kN at peak, and around 65 kN on the plateau, whatever the dispersions. This validation
criterion must be measured on the rails level.
The transversal efforts must be the smallest possible, and they may not exceed 5 kN along Y and 5 kN along Z on both rails.
No inclination of the absorber towards Y or Z may be observed during the tests on a subsystem and on a vehicle.
Compliance with the chronology:
- Crushing the beam towards the plate for the reparability system
- No deformation may occur on the rails during the collapse of the reparability system
No bending of the plate as a result of a test is allowed (subsystems and on a vehicle): flatness within the plan tolerances.
The performance must be identical on the left and on the right
The absorber squares must be aligned on the rail squares (YZ plane section).
The maximum TR (Tolerance Range) to be guaranteed for the alignment of the absorber-rail neutral axes is of 2 mm
Robustness:
Angle of the wall: the supplier must perform robustness tests with wall angles of 8 and 12
A robustness/sensitivity study in relation with all the influencing parameters (geometrical characteristics, mechanical
characteristics, temperature effect, welding characteristics, surface finishes ...) must be considered for each development phase. The
supplier must present the details of his robustness study, included on the response to consultation.
Digital Validations:
The digital validation must be performed on the subsystem model supplied by us as it is; no modification may be made without
our approval (the weight, the limiting conditions, and the adequate instruments are supplied in this model).
The supplier can size his system in the digital line of his choice, but the presentation of the results and the deliverables must
comply with our digital line.
Page 7/37
FR1 validation:
Output data:
Energy of the reparability system (sum between the internal energy and the hourglass energy of all the parts of supplier's
responsibility)
X effort/sinking curve of the system (effort measured in the section LEFT-RAIL-SECTION (x=-700) of the rail, sinking
measured with the TH (time history) node of the vehicle: "VEHICLE").
Y effort/sinking curve of the system (effort measured in the section LEFT-RAIL-SECTION (x=-700) of the rail, sinking
measured with the TH node of the vehicle: "VEHICLE").
Z effort/sinking curve of the system (effort measured in the section LEFT-RAIL-SECTION (x=-700) of the rail, sinking
measured with the TH node of the vehicle: "VEHICLE").
Effort/time curves (sections identical to the previous curves)
System deformations
Validation criteria:
The absorbed energy against the sinking, obtained by integrating the effort/sinking curve
The max. efforts (normal and transversal)
The maximum sinking
FR2 validation:
Output data:
Plastic deformations stretchers before saturation of the system
Validation criteria:
Rails: no part of the rails (left and right) may show more than 10 related items that show a plastic deformation above 5%
on the maximum sinking (saturation of the reparability system)
Other parts: no item of the other parts of the structure may show plastic deformations above 5% on the maximum sinking
(saturation of the reparability system)
Physical Validations:
Left and right side impacts on the beam (with tow ball) in compliance with the ALLIANZ procedure
Number of tests per configuration: See the integration and validation plan, in point 5.7.1.
Manufacturing the test means and performing the tests are of supplier's responsibility
Test of subsystem no. 1 (FR1 validation):
Trolley with complete reparability system or drop-weight tower sent towards a fixed leaning wall
Output data:
Effort curves along the directions X, Y, and Z (effort measured by three-axis cells placed between the plates of the tested
system and the trolley)
The effort/sinking curve on the impact side and on the side opposite to the impact (effort measured by three-axis cells
placed between the plates of the tested system and the trolley, sinking measured between the bumper and the plate)
Effort/time curves (sections identical to the previous curves)
A high-frequency video of each test (above, behind and in front, frequency of 1000 images/sec)
Calculation of the efficiency index of the system
The supplier must evaluate the efficiency index of his system using the following formula: Ieff=Eabs/Emax
Where Emax = [maximum effort allowed on the platform (Fadm)] x [Total available length (Ldispo)]
And Eabs is the energy absorbed by the complete reparability system.
Page 8/37
Validation criteria:
The absorbed energy against the sinking, obtained by integrating the effort/sinking curve
The max. efforts (normal and transversal)
The maximum sinking
Output data:
The effort/sinking curve on the impact side and on the side opposite to the impact (effort measured by three-axis cells
placed between the rear of the false spars and the trolley, sinking measured between the bumper and the plate)
Effort/time curves (sections identical to the previous curves)
A high-frequency video of each test (above, behind and in front, frequency of 1000 images/sec)
Validation criteria:
Absorbed energy
No deformation of the rails. No deformation of the vehicle structure items before reaching the absorbed energy (the
energy must be measured by integrating the effort/sinking curve)
Any physical trial run will have to be followed of a phase of correlation calculations/tests in order to justify the numerical results
presented by the supplier.
Page 9/37
5.1.2 ECE 42
Regulation requirement and conditions:
Functional Requirement:
Compliance with the ECE42 regulation.
Test conditions
Load case:
Bumper at ambient temperature
Empty weight in kg
1225 kg
1225 kg
1225 kg
Laden weight in kg
1450 kg
1450 kg
1450 kg
915
Reference
line
R3
114
15
76
305
610
406
R13
Ground
R25
R102
Page 10/37
Performance criteria:
The maximum dynamic sinking of the system must be smaller than 50 mm.
For your information, the acceptance criteria of the ECE42 test are the following:
*Lighting and signaling in operation
*Maneuverable doors
*no leaks of liquids (cooling fluid, fuel...)
*EFU (Electric Fan Unit) and exhaust system in operation
Digital Validations:
Upon each presentation of the results of the design, the supplier must present at least the following items:
To check the requirements, the supplier must assure that no deformation appears on the structure of the vehicle,
except on the front plastic parts.
No deformation may appear on the reparability system.
The supplier must present a sinking/time law for each load case.
The validations cannot be performed on a rigid frame. The vehicle is guided along X, and the vehicle motion is free
along X.
Physical Validations:
Number of tests per configuration: See the integration and validation plan
Manufacturing the test means and performing the tests are of supplier's responsibility
Output data:
For each test phase, the mandatory physical validations are:
- 3 tests on a subsystem. Parking impact in compliance with the most critical load case calculated (this configuration must be
determined in collaboration with us) on a rigid frame
o speed: to be determined in compliance with the most critical configuration
o weight of the trolley: to be determined in compliance with the most critical configuration
o stop to be determined in compliance with the most critical configuration
o beam/stop relative position: vehicle configuration
For these parking impact tests, the required results are:
high frequency video: 3 views (top, left, right)
effort (along the 3 axes) behind the system
effort on the wall behind the stop
measurements of the acceleration (along the 3 directions) at the level of the stop
pictures after the tests (beam deformation)
measurement of the possible residual sinking before and after each test (modification of shape of the beam)
Validation criteria:
Page 11/37
Test conditions
Speed: 56 km/h
Recovery equivalent to 40 % of the vehicle
Vehicle weight: 1.225 kg
Justification:
Structure high speed front impact DC
Data provided to the supplier:
CAD file for the assigned volume before impact.
Numerical calculus model
Performance criteria:
The complete system must dissipate at least 7 kJ on a vehicle, whatever the product/process dispersions
The maximum effort transmitted along X must be of 90 KN at peak and of 80 KN on the operation plateau ( This validation
criterion must be measured at the false spars).
The transversal efforts must be the smallest possible, and they may not exceed 6 KN along Y and 6 KN along Z on both false
spars.
The max. bending moment around Z must be of 1.2 106 N.mm before the system is destroyed
No inclination of the absorber towards Y or Z may be observed during the tests on a subsystem and on a vehicle.
There may be no breaking of the complete system:
- No breaking of beam that results in separation between the system/panel/false spars throughout the
impact.
- The beam-absorber connection must resist to the efforts so as not generate breakings
The complete system may not disturb the false spars bundling (the system may not reduce the energy absorption potential of the
false spars)
Robustness:
A robustness/sensitivity study in relation with all the influencing parameters (geometrical characteristics, mechanical
characteristics, temperature effect, welding characteristics, surface finishes ...) must be considered for each development phase. The
supplier must present the details of his robustness study, including upon the response to consultation.
Page 12/37
Digital Validations:
The digital validation must be performed on the subsystem model supplied as it is; no modification may be made without approval
(the weight, the limiting conditions, and the adequate instruments are supplied in this model).
The supplier can size his system in the digital line of his choice, but the presentation of the results and the deliverables must
comply with our digital line.
Impacts in compliance with procedure ECE R94
FR1 (Functional Requirement) validation:
Output data:
Energy of the reparability system (sum between the internal energy and the hourglass energy of all the parts of supplier's
responsibility)
X effort/sinking curve of the system (effort measured in the left rail, sinking measured between the TH node of the left
bumper and the TH node of the left plate positioned after the absorber).
System deformations
Validation criteria:
The absorbed energy against the sinking.
The max. efforts (normal and transversal)
The maximum sinking
The absence of breaking of the system
The absence of inclination of the system
FR2 validation:
Output data:
Curve Moment Mz
Y effort (effort measured in the rails).
Z effort (effort measured in the rails).
Validation criteria:
Conformity Fy, Fz to 6 kN
Conformity, Mz with 1.2106 N.mm
Physical Validations:
Number of tests per configuration: See the integration and validation plan
Manufacturing the test means and performing the tests are of supplier's responsibility
Subsystem test (FR1 and FR2 validation):
Rigid frame with complete reparability system, hit by a mobile rigid wall
Output data:
Effort curves along the directions X, Y, and Z (effort measured by three-axis cells placed between the plates of the tested
system and the frame)
The effort/sinking curve wall/platinum (effort measured by three-axis cells placed between the plates of the tested system
and the frame, sinking measured between the bumper and the plate)
Curves Moments My and Mz/time (idem curved effort/depression)
a high-frequency video of each test (above, behind and in front, frequency of 1000 images/sec)
Page 13/37
Validation criteria:
Any physical trial run will have to be followed of a phase of correlation calculations/tests in order to justify the numerical results
presented by the supplier.
The rings for the tests and their model for the digital validation must be supplied by us
Page 14/37
1
2
= - 2
For the digital dimensioning, the extreme load cases have been considered (see the red points in the figure above).
See appendix transportability for details on the efforts and their directions
Page 15/37
z
Vehicle axis (X)
E
80
45
60
3
- 60
1
Direction of the max. sea securing effort (standard B20 1001)
For the digital dimensioning, the extreme load cases have been considered (see the red points in the figure above).
See appendix transportability for details on the efforts and their directions
z
Vehicle axis (X)
E
80
45
4
15
- 15
For the digital dimensioning, the extreme load cases have been considered (see the red points in the figure above).
See appendix transportability for details on the efforts and their directions
X2
Vehicle axis (X)
25
25
25
Y2
F = 1300 daN.
X2
X
25
25
Y2
Page 17/37
Angle d'application par rapport l'axe vhicule selon effort dans le plan
horizontal
100
Angle ()
80
60
40
20
-1
-0,8
-0,6
-0,4
-0,2
0
-20 0
F/MTAC
0,2
0,4
0,6
0,8
-40
-60
-80
-100
Angle d'application par rapport l'axe vhicule selon effort dans le plan vertical
100
Angle ()
80
60
40
F/MTAC
20
0
-1
-0,8
-0,6
-0,4
-0,2
-20 0
0,2
0,4
0,6
0,8
-40
-60
-80
-100
F = -0.8 x
GVWR
= 25
= 10
= -10
F = -0.4 x
GVWR
= 25
= 20
= -40
F = 0.4 x
GVWR
= 25
= 20
= -40
F = 0.8 x
GVWR
= 25
= 10
= -10
Page 18/37
Thus, the analysis of the following four load states proves necessary for complying with the envelopes presented above:
o
o
o
o
F=
F=
F=
F=
See appendix transportability for details on the efforts and their directions
Point A
Point B
Tow Ring
Point P
Area to be analyzed: Base of the ring.
service life
dynamic towing
requirement
category
exceptional effort
aesthetics
max. effort
lifting on a truck
max. effort
aesthetics
computed criterion
no initiation of breaking
minimize the risks of contact
no initiation of breaking
limited and restricted plasticization (Neuber criterion)
no risk of buckling under compression
compliance with the deformation cone specified in CAD.
no initiation of breaking
limited and restricted plasticization (Neuber criterion)
compliance with the deformation cone specified in CAD.
Page 19/37
max. effort
aesthetics
fatigue
aesthetics
no initiation of breaking
limited and restricted plasticization (Neuber criterion)
compliance with the deformation cone specified in CAD.
no incipient crack by fatigue on the parts and on the welded
connections
compliance with the deformation cone specified in CAD.
service life
dynamic towing
requirement
category
exceptional effort
aesthetics
max. effort
lifting on a truck
max. effort
aesthetics
max. effort
aesthetics
sea securing: fatigue
fatigue
aesthetics
test criterion
no initiation of breaking
minimize the risks of contact
no initiation of breaking
to dismount the ring and to reassemble a new ring at
bottom and the hand
no risk of buckling under compression
compliance with the deformation cone specified in CAD.
no initiation of breaking
to dismount the ring and to reassemble a new ring at
bottom and the hand
compliance with the deformation cone specified in CAD.
no initiation of breaking
to dismount the ring and to reassemble a new ring at
bottom and the hand
compliance with the deformation cone specified in CAD.
no incipient crack by fatigue on the parts and on the welded
connections
compliance with the deformation cone specified in CAD.
For the exceptional efforts, the absence of initiations of breaking must be guaranteed, and also that the system - even if possibly
deformed - allows the client continuing the towing to the nearest garage.
For the fatigue, an analysis by inspection must be performed after the test, in compliance with the standardized procedures, to
check the absence of cracks in the parts and in the welding inside the system.
Page 20/37
Structure (STR):
STR part
Type
Function
Fastenings / geometry
Screw + pilot
Geometry
Geometry
Geometry
Outside equipments:
EFAA parts
Type
Interfaces
Front bumper *
Geometry
Proximity
Fastenings
ARTIV *
Fastenings
Page 21/37
5.6.1 Weight
The Weight objective must be applied to the entire perimeter subject to consultation.
Reparability system
Weight 5.5 kg
5.6.2 Cost
See the cost objectives in the PURCHASE file.
5.6.3 Deadlines
See the deliverables and the development planning in the MANAGEMENT AND QUALITY ASSURANCE CLAUSES file.
Page 22/37
5.6.5 Materials
5.6.5.1 Generalities
Two hypotheses are taken into account:
Recycling
This paragraph specifies the treatment constraints at the end of life of the object, in compliance with the European Directive
2000/53/EC for the End-of-Life Vehicles (ELV).
These constraints may be resumed as follows:
Cleanup
In compliance with the Directive 200/53/EC, all the elements to clean up at the end of life of the vehicle must be fit for treatment,
either by breakdown, by neutralization, or by extraction. In the end, the cleanup of the vehicle must be possible.
As a consequence, the items subject to cleanup must be fit for cleanup in compliance with the procedures MXP_EMR01_0053
"Definition of the cleanup requirements for a vehicle project" and MXP_EMR01_0048 "Operating range of the items to clean up"
Recycled materials
The vehicles must use an increasing proportion of recycled materials.
The applications of recycled materials possible at the same cost and same Spec are performed and communicated through the
MACSI application.
Page 23/37
Material marking
The plastic parts are marked in compliance with the standard B20 1315/D and in compliance with the Directive 2003/138/EC.
The elastomer parts are marked in compliance with B20 1315/D and in compliance with the Directive 2003/138/EC.
The material grades and the thermal treatments, if necessary, as well as the related European standards.
The coatings.
The standards concerning the specific of the part or of the subassembly (pins, nuts, crimping, etc.)
The standards concerning the functions that must be ensured by the organic products.
Requirement
The supplier must propose materials that allow meeting the functional
requirements and the required anticorrosion performances for the
subassembly.
Appearance:
The used products must be fit for manufacturing the specified parts and must
be free of faults in detrimental to their normal use.
The surface of the parts must be clean, free of oxidation, scale, and adhesive
tags.
Safety:
The parts may not show flashes or areas that might cause injuries to the
operator.
Flat products
Material choice
The supplier must make his material choices in compliance with the following rules:
Prefer the material choice among the material grades and lines validated by us.
If the material grade and/or the lines are not validated, the supplier must prefer a material producer in our panel. In addition,
the supplier must make sure of the compatibility of the material with our downstream manufacturing processes (details in the next
paragraph).
If the proposed material is not validated by us and/or the material producer is not in our panel, our approval is mandatory. In
addition, the supplier must make sure of the compatibility of the material with our downstream manufacturing processes (details in the
next paragraph).
Page 24/37
Risks of elimination for the material compatibility with our manufacturing process
In the cases and , the supplier must make sure of the compatibility of the proposed material with our manufacturing process
(TTS, electrophoresis, painting) by meeting the following requirements:
Reference documents
Requirement
Traceability:
The traceability of the prototype parts and of the series parts must allow
retrieving, if necessary:
The information on the material production runs;
The production runs of manufactured parts corresponding to the parts
sampled for checking.
Surface finish:
B53 3059/F
B54 1059/A
The supplier must make his material choices in compliance with the following rules:
Prefer the material choice among the material grades and lines validated by us.
If the material grade and/or the liner are not validated, the supplier must prefer a material producer in our panel.
If the proposed material is not validated by us and/or the material producer is not in our panel, our approval is mandatory.
Reference documents
Requirement
B10 1110/C
B53 3020/C
B53 3050/C
B53 3070/F
B53 3072/E
Page 25/37
Reference documents
Requirement
R21 0001/D
For the parts identified as Safety or Regulation, the material thinning must
comply with the standard R21 0001/D.
Stamped parts:
o
For some parts, as indicated in the plan, they must comply with the
thickness paragraph of the standard B10 1110/C.
B53 3072/E
B10 1110/C
B13 1510/A
Joined blanks: Thickness ratio in compliance with the standard B13 1510/A
Steel shapes:
o
The supplier must make sure that the thickness of the material is not
modified by the forming method, especially in the radius areas.
B53 3072/E
Tubes
The tubes must comply with the requirements defined by the following standards:
Reference documents
Requirement
B53 5020/B
B53 5040/B
B53 5043/C
B53 5046/B
B53 5046/B
Requirement
B53 1060/A
Cold drawn steel wire rods for general purpose -Technical and administrative
specifications
B53 1063/A
Cold drawn steel wire rods for general purpose - Metallurgical specifications
B53 1066/A
Cold drawn steel wire rods for general purpose - Dimensional specifications
Page 26/37
Requirement
B53 1040/D
B53 1043/D
B53 1046/E
Designation
B53 3210/E
B53 3220/H
B53 3830/D
B53 5020/B
B15 4210/C
B15 4101/D
B15 4102/B
B15 3320/A
Page 27/37
Requirement
Requirements for all the parts:
In normal transport, handling, and storage conditions, this protection must
guarantee products that do not show any traces of oxidation within an interval
of 3 months from the date when the product is made available in the factory
with the initial packaging.
This protection must be compatible with the subsequent manufacturing
operations (assembling by welding or by gluing, TTS / electrophoresis / painting
process, etc.).
The oils compatible with the gluing and surface treating products
subsequently applied to the parts are to date the following:
o
The oil amount must comply with the standard B53 3050/D in compliance
with the test method D65 5353.
If shaping the parts (stamping, forming ...) needs specific lubrication, the
supplier must make sure of its compatibility with the rest of the process. If the
used lubrication product is incompatible with the process, the parts must be
degreased and greased again using a compatible product with the process.
Material choice
Case of an assembly built-in upon reinforcing
The supplier must make his material choices in compliance with the following rules:
Prefer the material choice among the products validated by us for the concerned function.
If the proposed product is validated, but it is applied on a support which's material and/or line are not validated by us, the
supplier must demonstrate that the product meets the requirements of the functional characteristics demanded.
If the proposed product is not validated by us, the supplier must demonstrate that the product meets all the requirements
demanded.
Page 28/37
Reference documents
Description
MXP_CEB02_0027*
Technical specifications for the organic products for outsourced parts and
subassemblies of the body in white
*: document subject to reviewing, available upon request and with the approval of the Purchase Division
The insert fastenings, depending on their nature, must comply with the following requirements:
Reference documents
Requirement
C10 0040/F
C20 0040/B
Welded nuts
B11 1400/D
Threaded flanges
B11 1500/OR
Crimped nuts
Description
B13 1226/D
B13 1227/D
B13 1340/OR
B13 1520/A
B13 1540/P
ARC methods - MAG (Metal Active Gas) welding of steel, MIG (Metal Inert
Gas) braze welding of steel
B13 6120/A
Test method for assemblies of coated or non coated flat products by selfpiercing rivets
B13 7120/A
Test method for assemblies of coated or non coated flat products by stamping
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Generalities
Coating is required for all the steel parts of the system (coating optimization is required in accordance with the synthetic AVC
(Accelerated Vehicle Corrosion) synthesis tests results).
In compliance with the body anticorrosion STO, the FR and RE impact absorption systems are at stress level 3; they must comply
with the requirements listed below, in compliance with the anticorrosion specification guide for the body, the standard B15 5050
index M (Paint coating of finished vehicles).
The requirements described in the anticorrosion GTS (General Technical Specification) are based on the exchange of experience
on the vehicle appearance, and they are issued of the anticorrosion guide.
They must be considered the closest to the "anticorrosion bare minimum"target durations: appearance > 6 years (5 years in
client use + 1 year of storage) and anti-drill > 13 years (12 years in client use + 1 year of storage). The functional conservation
objectives are set to 8 and 6 years, but the body is little concerned beyond the door mechanisms. The internal objectives of period
without corrosion that impacts the safety are of 16 years (15 years in client use + 1 year of storage).
Requirement
Requirements for all the parts:
The coating of each part must be checked in compliance with the specific test
procedures listed in the standards specific to each type of coating. Depending
on the anticorrosion option retained by the supplier for each component of the
FR and RE impact absorption systems, the acceptance requirements for each
tested coating must comply with the corresponding standard.
However, upon consultation, a supplier can propose a coating that was not
specified (new product or method), on the condition that the supplier
demonstrates that the proposed coating results in a protection at least
equivalent to that of the coating specified by us, on one hand, and that the
proposed coating is compatible with our downstream manufacturing process,
on the other hand. In this case, the supplier must also send some parts to the
corrosion service for validating the coating.
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Requirement
Steel parts made of flat products:
all parts must have a G10/10 or EZ10/10 coating in compliance with the
standards B53 3220/H or B53 3210/E, respectively.
Steel screws and bolts associated to the impact absorption system:
B15 4101/D
B15 4102/B
B15 3320/A
Authorized protections:
Electrolytic zinc deposit in compliance with the standard B15 4101/D
Bulk electrolytic zinc: ZNI A3P or ZNI N3P in compliance with the standard
B15 4102/B
Lamellar zinc: ZLV MGO in compliance with the standard B15 3320/A
Steel tow ring support:
Authorized protections:
B15 4102/B
Bulk electrolytic zinc: Z10 in compliance with the standard B15 4102/B
B15 3320/A
Lamellar zinc: ZLV MGO in compliance with the standard B15 3320/A
On this part, priority is given to protecting the threads so as to guarantee the
fitness for assembly of the tow ring after 30 AVC cycles.
Reference documents
B53 3220/H
B53 3210/E
Requirement
Steel parts made of flat products:
all parts must have a G10/10 or EZ10/10 coating in compliance with the
standards B53 3220/H or B53 3210/E, respectively.
Steel screws and bolts associated to the impact absorption system:
Authorized protections:
B15 4101/D
B15 4102/B
Bulk electrolytic zinc: ZNI A3L or ZNI N3L in compliance with the standard
B15 4102/B
B15 3320/A
Lamellar zinc: ZLV MGO or ZLV MGL in compliance with the standard B15
3320/A
Steel tow ring support:
Authorized protections:
B15 4102/B
Bulk electrolytic zinc: Z10 in compliance with the standard B15 4102/B
B15 3320/A
Lamellar zinc: ZLV FGO or ZLV FGL in compliance with the standard B15
3320/A
On this part, priority is given to protecting the threads so as to guarantee the
fitness for assembly of the tow ring after 30 AVC cycles.
In case of an impact absorption system built-in upon our assembly stage, the table below describes the additional requirements for
the complete assembled system.
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Reference documents
Requirement
Steel FR impact absorption system:
Visible and graveled system:
B15 5050/M
B15 5050/M
At the end of the test, all the safety functions of the FR and RE impact absorption systems and of the component parts of
the FR and RE impact absorption systems must be obtained within the tolerance range.
In order to guarantee the 6 years of appearance without "red rust", no red corrosion is allowed on the visible parts of the
vehicle, whatever the source of the corrosion (e.g.: leak from a hidden part) after 30 AVC cycles.
The screws and bolts associated to the component parts of the FR and RE impact absorption systems may not show red
corrosion after 10 AVC cycles.
As the tow ring is a regulation part, screwing it in the tow ring support must be possible after 30 cycles.
At the end of the sanding - graveling tests and of the AVC, the requirements must be adapted in accordance with the
results.
5.6.7 Interchangeability
The interface between the body and the bumper frame must be removable without specific tools. The bumper frame / front
absorber system must allow removing / reassembling without degrading the product and its performances, or those of the neighboring
parts.
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Presentation of the calculation and test results in compliance with the IVP and the TS (Technical Specification)
Calculation and test correlation upon each validation, depending on the process adjustments
Presentation of the calculation and test results in compliance with the IVP and the TS
Calculation and test correlation upon each validation, depending on the process adjustments
Presentation of the justification file with all tests and calculation correlations and with the presentation of the
optimizations proposed for the Tolling Go-Ahead.
Presentation of the calculation and test results in compliance with the IVP and the TS
Calculation and test correlation upon each validation, depending on the process adjustments
Justification file that integrates all the evolutions
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The disclosure by our side of auxiliary digital models that the supplier considers necessary for performing his dimensioning
(partial models of the vehicle ...) must be the subject of a specific confidentiality contract. This phase must be considered only if the
first proposals of the supplier are estimated convincing.
5.8 Failsafe operation and List of the Criticality 3 and 4 DE (Dreaded Events)
The system must maintain its functional characteristics throughout the service life of the vehicle. The FMECA (Failure Modes,
Effect and Criticality Analysis) results must meet our requirements.
The Failsafe Operation tests and calculations must be integrated into the validation plan, and the QMC (Quality Management
Clauses) deliverables into a specific section. The supplier must describe the methods employed, as well as all the actions that
guarantee the absence of dreaded events, in terms of technical solutions, specific design, calculation, digital simulation, physical
tests...
The Criticality Index is an estimation of the effect of the dreaded event considered in terms of inconvenience for the customer,
of costs of repairing, or of individual risk. The dreaded events are graded in compliance with the following grading system:
Level
1
green
2
yellow
3
orange
4
red
Definition
Comments
Dissatisfaction or degradation of a
General performances of the vehicle preserved. The user
vehicle function
can continue using his vehicle. No intervention required.
Occurrence of disturbing symptoms. The user can
Loss of a vehicle function.
continue using his vehicle, but urgent intervention is
required.
Impossibility to drive or impossibility to reach the
destination because of the loss of a main function, or
The vehicle is non-operational.
because of non-compliance with the regulations (risk of
fine).
Impossibility to park safely (risk of inviolability).
Risk of corporal injury to individuals.
For the studied system, the dreaded events have been declined through the Failsafe Operation requirements.
Criticality 3 requirements:
The criticality 3 dreaded events for the bumper frame system are the following:
Objective
after 7 years
Failure mode
Breaking
securing
of
the
system
upon
sea
10-3
Failure of mechanical
origin (breaking)
10-3
Failure of mechanical
origin (breaking)
The supplier must demonstrate the compliance with the availability objectives, with an index of reliability of 75%.
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Criticality 4 requirements:
The criticality 4 dreaded events for the bumper frame system are the following:
Objective
after 15 years
Failure mode
10-6
Failure of mechanical
origin
10-6
Failure of mechanical
origin
10-6
Failure of mechanical
origin
10-6
Failure of mechanical
origin
The supplier must implement a design that allows eliminating the 1st order cuts for the safety failure modes.
The supplier must demonstrate the compliance with the safety objectives, with an index of reliability of 90%.
6. APPENDIXES
6.1 Appendix 1 Transportability
FR ring
Traction
nominal
nominal
1
2
3
4
Compression
(around
Y)
0
0
2
-2
-2
2
FX
(daN)
-1186
1186
1184
1184
1184
1184
FY
(daN)
0
0
41
41
-41
-41
FZ
(daN)
0
0
-41
41
41
-41
In addition, an ultimate compression calculation must be made, in order to determine the crossmember buckling mode and effort.
For this calculation, the direction of the most dimensioning effort among the five compression case must be chosen, and the effort
standard must be increased until buckling.
Traction
1
2
3
4
(around Z)
-60
60
-60
60
(around Y)
80
80
45
45
FX
(daN)
-223
-223
-160
-160
FY
(daN)
386
-386
277
-277
FZ
(daN)
-79
-79
-320
-320
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(around Z)
-15
15
-15
15
1
2
3
4
Traction
(around Y)
80
80
45
45
FX
(daN)
-138
-138
-99
-99
FY
(daN)
37
-37
27
-27
FZ
(daN)
-25
-25
-102
-102
FX
(around Z) (around Y) (daN)
25
40
-903
FY
(daN)
-421
FZ
(daN)
-836
Traction
F=0.4 GVWR
1
2
3
4
(around Z)
-25
-25
25
25
(around Y)
-40
20
-40
20
FX
(daN)
-658
-808
-658
-808
FY
(daN)
307
377
-307
-377
FZ
(daN)
-610
324
-610
324
1
2
3
4
(around Z)
-25
-25
25
25
(around Y)
-10
10
-10
10
FX
(daN)
-1693
-1693
-1693
-1693
FY
(daN)
789
789
-789
-789
FZ
(daN)
-329
329
-329
329
1
2
3
4
(around Z)
-25
-25
25
25
(around Y)
-40
20
-40
20
FX
(daN)
658
808
658
808
FY
(daN)
-307
-377
307
377
FZ
(daN)
610
-324
610
-324
1
2
3
4
(around Z)
-25
-25
25
25
(around Y)
-10
10
-10
10
FX
(daN)
1693
1693
1693
1693
FY
(daN)
-789
-789
789
789
FZ
(daN)
329
-329
329
-329
FR ring
Traction
F=0.8 GVWR
FR ring
Compression
F=-0.4 GVWR
FR ring
Compression
F=-0.8 GVWR
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