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CIRCULAR 4/01-9-1

TEST PROCEDURES

ADR 4/01 - SEAT BELTS

“A Guide for Inspectors”

This Circular is relevant to the Third Edition of the

Australian Design Rules gazetted as

National Standards under the Motor Vehicle Standards Act 1989.

Issue 2: of 48 CIRCULAR 4/01-9-1

CIRCULAR 4/01-9-1 of 48 Issue 2:

CONTENTS

Page

1 SCOPE 5

2 SELECTION OF TEST COMPONENTS 5

3 IDENTIFICATION OF TEST COMPONENTS 5

4 NUMBER OF TEST SEAT BELTS 5

5 TEST EQUIPMENT AND TEST PROCEDURES 6

6 ORDERS OF ACCURACY AND CALIBRATION 40

7 SUMMARY OF EVIDENCE REPORT 40

8 PROCEDURE FOR DESIGNS WITH CERTIFICATIONTO ALTERNATIVE STANDARDS 40

9 REFERENCES 41

ANNEX A Test Seat and Anchorages for the Dynamic Test. 42

ANNEX B Component Boundary Location 43

ANNEX C Dummy Dimensions 44

ANNEX D Preparation and Conditioning of Test Specimens for Retractor Function 45(AS 2597 - 9 , 1983)

ANNEX E Apparatus to Test Locking of Type 4N Retractors. 48

TEST PROCEDURES CIRCULAR 4/01-9-1


CIRCULAR 4/01-9-1 TEST PROCEDURES


1 SCOPE

This procedure, when read in conjunction with the DesignRule and other Circulars issued by the Administratorprovides sufficient information to conduct and audit testson Seat Belts to demonstrate compliance with AustralianDesign Rule 4/00 and 4/01. As ADRs 4/00 and 4/01 haveidentical test requirements, this circular applies to bothADRs.The /01 Rule differs from the /00 Rule inapplying/changing seat belt requirements to categoriesMD2, MD3, MD4, ME, NB2 and NC vehicles. It alsodeletes ECE 16/00 to 16/03 as acceptable “AlternativeStandards”.Test procedures from Australian Standards for testsreferred to in the ADR have been included in this Circularby arrangement with Standards Australia.For convenience reference to the ADR and AustralianStandard clause numbers are quoted in brackets againsteach appropriate Section of this procedure.The equipment, orders of accuracy and step by stepactions described in this procedure are drawn from thestandards and recommended practices quoted in the ADRand Australian Standards and from accepted laboratoryand testing practices. While conformance with thisprocedure is sufficient to demonstrate compliance with theADR, other equipment, orders of accuracy and proceduresmay be used provided it can be shown that theydemonstrate compliance with the ADR.This ADR calls for tests which demonstrate that:(i) The seat belt assembly meets certain fit and adjustmentrequirements.(ii) The seat belt assembly and components meet certainstrength and durability requirements.(iii)The seat belt assembly shall withstand dynamic loadsimposed by the specified test procedure.This procedure is intended primarily as a guide forofficers of the Australian Department of Transport andCommunications or agents acting on behalf of theAdministrator when they carry out audit inspections oftest facilities or witness tests for compliance with theADR. This and other circulars dealing with testprocedures for ADRs may also be useful to vehiclemanufacturers and testing organisations.Nothing in this circular, however, absolves themanufacturer from complying with the requirements asspecified in the ADR which always remains the primaryreference.

2 SELECTION OF TEST COMPONENTS

This procedure applies to all seat belt assemblies invehicles subject to the Design Rule. It includes static seatbelts, lap/sash and lap belts and also emergency lockingretractor (ELR) lap/sash belt systems.

3 IDENTIFICATION OF TEST COMPONENTS

All test seat belts and fittings, adjusters, sash guides andretractor assemblies shall be structurally representative ofthe design condition as reflected in the productiondrawings.Further, for dynamic testing, the test facility must ensurethat kinematically the mechanisms are representative ofthe design conditions.If production parts are being tested they should be drawnfrom a batch which has passed normal quality assuranceprocedures. They should then be identified against theproduction drawings. If prototype parts are being testedthey should be individually inspected on a component bycomponent basis for both dimensional and material(composition, heat treatment and finish) compliance withthe drawing.In either case the revision or issue status of the drawing towhich the assemblies have been checked must be statedon all test records.Finally, a build record should be prepared showing thesource and status of all material used for the test seat beltassemblies. The record should be of sufficient detail tocompletely identify the subject material.

4 NUMBER OF TEST SEAT BELTS

The tests required for each style of belt (static, ELR lap orlap/sash) should be studied so as to arrive at the number ofseat belt assemblies to demonstrate Compliance with theADR . Except where preconditioning of the seat beltassembly is required before conducting tests, the testassembly, comprising each component, and the welding,shall be dry, unused and not previously tested. Test piecesof webbing for determination of dry tensile breakingstrength and elongation shall be taken from adjacentwebbing or from the same roll of webbing

5. TEST EQUIPMENT AND TEST PROCEDURES

5.1 Introduction



This Section describes the Equipment required and thetest procedures each of the series of tests required todemonstrate compliance with ADR 4/01. In many casesthe relevant Data from the Australian Standards has beenreproduced by arrangement with Standards Australia.Where any part of the extracted Australian Standard is notrelevant for ADR 4/01 it has had a line drawn through it.The Australian Standards used in this section are:

AS 2596-1983. Seat Belt Assemblies for Motor VehiclesAS 2597-1983. Methods of Testing Seat Belts

AS 1753 - 1983 Webbing for Restraining Devices forOccupants of Motor VehiclesAS E35 Pt 1 and Pt 11 1970 have not been used in thiscircular

Index of Tests RequiredSeat Belt Assembly

Circular ADR Title AS 2596 AS2597

4/01 Clause Section

Clause

5.2 4.13 Dimensional Test 7

5.3 4.2.7 Fatigue Resistance of a Flexible member 7 3

5.3.1 Analysis of Test Results 7

5.4 4.2.7 Potential for Inadvertent Buckle Release 9(b) 4

5.4.1 Analysis of Results

5.5 4.2.7 Adjustment Device Forces 10(e)

5.5.1 Analysis of results 6

5.6 4.2.7 Locking Angle of Tilt lock 10(e) 7

Adjustment Device


5.7 4.3.3 Free End Strength 10g 8


5.8 4.5.1 Webbing Durability of Adjusters 6.2.1 1


5.9 4.5.1 Webbing Durability Sash Guide 6.2.2 2

5.9.1 Analysis

5.10 4.5.3 Buckle Spring Fatigue Resistance 9(j)


5.11 4.6.2 Static Strength of Seat Belt 14.1 10

4.8 Assembly (after retractor durability test) 9


5.12 4.6.2.2. Webbing Retractor Force 11.3 11

5.12.1 Analysis of Test Results

Tests on Retractor

5.14 Determination of Retractor Locking

5.14.1 4.6.4.1 Retractor Locking under Acceleration 11.6.3 12

Analysis of Test Results

5.14.1.2 4.6.4.2 Acceleration of Strap from Retractor 11.6.3. 12

5.14.1.3 4.6.4.3 Mechanical Failure of Retractor Mechanism 11.4

5.14.1.4 4.6.4.4 Signal or Power Failure to Retractor 11.4

5.14.1.5 4.6.4.5 Retractor Tilt 12

5.15 4.7 Dynamic Test 14.2 13


Circular ADR



4/01 AS1753

Clause Title Clause

5.16 4.8.1 Corrosion Resistance of Metal Parts 12 9

(preparation and conditioning of Test specimens

for retractor function)

5.16.2 Analysis of Test Results

5.17 Tests on Seat Belt Webbing Belt

5.17.1 4.2.7 Light Degradation 11.2

5.17.2 4.2.7 Webbing Strength

Dry Breaking Load 6

Wet Breaking Load 10

5.17.3 Load/Elongation of Webbing

5.18 Test for Type 4N Retractors (ADR 4/01 Appendix A

These tests are taken from ECE Regulation 16/04 Safety

Belts (ADR Appendix A) and apply to suspension seats (clause 4.14.4.2)

5.18.1 4.1.13 A ‘Type 4N Retractors is an ‘Emergency Locking Retractor’

which has a higher response threshold i.e. having special

properties as regard its use in vehicles other than passenger

cars. The requirements for Type 4N Retractors apply only to

Vehicle Categories MD3, MD4, ME, NB2 and NC.

5.18.2 App A,6.2.5.3 Locking of Type 4N Retractors

Analysis of Test Results.

5.18.3 App A 7. 6 Durability of Retractor Mechanism

Analysis of Test Results

5.18.4 4.4.7 Dynamic Test.



5.2 Dimensional TestsThese tests are usually conducted in the drawing officeusing full scale body layout drawings or computer aideddrafting techniques. The equipment required comprises a2-D manikin, see Circular 0-12-6, and normal draftingequipment.Access to the vehicle manufacturer’s occupant packagedrawings is required to determine the location of theSeating Reference Point and the Seating Reference Plane.From this data, using conventional drafting techniques thecomponent Boundary Location for the seat belt assemblycan be determined.5.2.2 COMPONENT BOUNDARY LOCATION5.2.2.1 The lines shown in Amen B side elevation areestablished as follows:5.2.2.2 Line A is a horizontal line 850 mm above the‘Seating Reference Point’.5.2.2.3 Line C is a horizontal line 680 mm above the‘Seating Reference Point’5.2.2.4 Line D is a horizontal line 150 mm below the‘Seating Reference Point’5.2.2.5 Line E is a horizontal line 75 mm below the

‘Seating Reference Points’5.2.2.6 Line FOS consists of 2 lines FO and OS and isconstructed as follows:5.2.2.6.1 Draw line FO parallel to the ‘Torso ReferenceLines’ and intersecting Line G at Point O, such that theextension of Line FO passes through the most ‘Forward’point on the ‘Seating Reference Locus’ and5.2.2.6.2 Draw a vertical Line OS intersecting Line G atPoint O;5.2.2.7 Line KPS consists of 2 Lines KP and PS and isconstructed as follows:5.2.2.7.1 Draw Line KP parallel to and 100 mm‘Rearward’ of Line FO (established above) intersectingLine OS at P; and5.2.2.7.2 Line PS is coincident with Line OS,5.2.2.8 Line G is a horizontal Line 380 mm above the‘Seating Reference Point’, intersecting the TorsoReference Line at Point N; and5.2.2.9 Line J is a horizontal Line 230 mm above theSeating Reference Point.



Section 5.3



Section 5.3

5.3.1 Analysis of Test ResultsFollowing the tests described above the flexible load bearing member shall be capable of sustaining a tensile load of 15kN for a minimum of 30 seconds. (AS 2596 - Clause 7)



Section 5.4

5.4.1 Analysis of Test ResultsThe buckle shall not have a potential for inadvertent release by the vehicle occupants. A buckle shall be deemed not tohave potential for inadvertent release by the vehicle occupants if, when tested in accordance with AS 2597.4 above,release is not caused. (AS 2596 - Clause 9b)



Section 5.5



Section 5.5

5.5.1 Analysis of ResultsThe adjustment device shall not require an adjustment force greater than 50 N when tested above. (AS 2596, Clause 10e)



Section 5.6



Section 5.6

5.6.1 Analysis of ResultsWhen tested as described above the tilt lock adjustment device shall lock at an angle of not less than 30 degrees andadjustment devices shall not require an adjustment force of greater than 50 N. ( AS 2596 - Clause 10e)



Section 5.7

5.7.1 Analysis of Results (Clause 4.3.3)The free end device shall have complied with this clause if after being subjected to a force of 9 kN for > 30 seconds it didnot pass through the anchor.



Section 5.8



Section 5.8

5.8.1 Analysis of Results (ADR 4/01 Clause 4.5.1)After the webbing and fittings have been subjected to the tests described in Section 7 above, the dry tensile strength of thewebbing shall not be reduced to less than 14.7 kN or 75% of the ‘dry breaking strength’ established in section 7(a) above.



Section 5.8



Section 5.9



Section 5.9

5.9.1 Analysis of Results (ADR 4/01 Clause 4.5.2)After the webbing, fittings, sash guide etc have been subjected to the tests described in section 7 above, the dry tensilestrength of the webbing shall not be reduced to less than 14.7 kN or 75% of the ‘dry breaking strength’ established insection 7(a) above.



Section 5.9



Section 5.10

5.10.1 Analysis of Results (ADR Clause 4.5.3)The force required to operate the buckle spring shall not be reduced by more than 20% after being subjected to the testsdescribed above. (AS 2596 Clause 10J)

(d) The percentage by which the buckle release force has been reduced.



Section 5.11



Section 5.11

5.11.1 Analysis of Results (ADR Clause 4.6.2) (AS 2596 Clause 14.1)After being subjected to the retractor durability test described in Annex D (AS 2597.9), the retractor shall be capable oflocking and when locked, either:: withstand a tensile load of not less than 9 kN applied to the Strap; or: be capable of sustaining the static test force when tested as a seat belt assembly or part seat belt in accord with the

procedures described above (Section 8) and the following1 (a) The seat belt assembly shall not separate from itself or from any anchor.(b) For lap belt assemblies the displacement of the test dummy shall not exceed 260 mm(c) For other seat belt assemblies the displacement of the test dummy shall not exceed 180 mm.(d) The slip of webbing through any single manual adjusting device shall not exceed 25 mm and total slip through allmanual adjusting devices shall not exceed 50 mm.(e) Buckle release force shall not exceed 112 N.(f) When buckle components may be latched to each other in different ways, the seat belt assembly shall comply with therequirement (a) to (e) for each way of latching. (AS 2596 - Clause 14.1)With the retractor unlocked it shall withstand a tensile force of not less than 9 kN applied to the strap.For the purpose of this test the ‘Strap’ shall be fully withdrawn and locking mechanisms shall be rendered inoperative.In the case where the retracting ‘Strap’ of a ‘Lap-Sash Belt’ is the torso ‘Strap’, the retraction force in the ‘Strap’ beforeand after the retractor has been subjected to the retractor durability test of Section 4.8, shall be not less than 2 N nor morethan 10 N, under the conditions described in Section 5.13 Webbing Retraction Force (ADR Clause 4.6.2)



Section 5.11



Section 5.12

(Annex D of ADR 4/01



Section 5.12

5.12.1 Analysis of Results (ADR 4.6.2.2) (AS 2596 Clause 11.3)Retractor Force in the strap shall be between 2 kN and 10 kN before and after the test described above.NOTE: This test is commonly carried out during the Retractor Durability Test referred to in Section 5.11



Section 5.13



5.14 Determination of Retractor Locking

5.14.1 Analysis of Test Results (ADR 4/01 Clause4.6.4.1)5.14.1.1 Acceleration of emergency locking dual sensitivelocking retractor (AS2596 - Clause 11.6.3 and AS2597.12Procedure B) Section 5.13.When the emergency locking retractor is tested byProcedure B AS2597.12 above it.• shall lock when the retractor and any associated

devices to sense acceleration are accelerated at notmore than 5m/s2, the peak acceleration being attainedin not less than 40 milliseconds

• Furthermore with a point on the external ‘Strap’ fixedthe locking device shall limit ‘Strap’ movement,measured from the time of application of theacceleration, to not more than

: 30 mm, when the ‘Strap’ is withdrawn to a point whichis 150 5 mm from the fully extended position; and: 80 mm, when the ‘Strap’ is withdrawn to points 450 5mm and 760 5 mm from the fully extended position, ifthe ‘Seat Belt Assembly’ includes sufficient ‘Strap’ toattain these extensions.• This requirement shall be met under positive and

negative acceleration in longitudinal, transverse andvertical directions, except that in case where thedevice is designed to lock when tilted to any angle inexcess of 45 degrees then the locking requirementneed be met for longitudinal and transverse directionsonly.

NOTE Sensing of acceleration to meet the requirementsof this Clause shall not be dependent upon rate of

withdrawal of ‘Strap’ from the retractor. In demonstratingthis requirement, any device dependent for sensing ofacceleration on withdrawal of ‘Strap’ from the retractormay be rendered inoperative. (ADR Clause 4.6.4.1)5.14.1.2 Acceleration of the Strap (ADR Clause 4.6.4.1)when the Emergency Locking Retractors is tested byProcedure C (AS2597.12) above and the ‘Strap’ isextended at an acceleration of not more than 20 m/s2

locking shall occur within 25 mm of ‘Strap’ extension.This requirement shall be met at an extrapolated pointrepresenting full extension based on test results achievedat points of extension which are less than the fullextensions by 150 5 mm, 450 5 mm, and 750 5 mm (ifavailable), respectively. (ADR Clause 4.6.4.2)5.14.1.3 Mechanical Failure of Retractor Mechanism.An ‘Emergency Locking Retractor’ shall be designed tolock automatically, or meet the requirements of section5.14.1.1 and 5.14.1.2 above upon any single mechanicalfailure of a spring which part of the locking mechanism(ADR Clause 4.6.4.3) (AS2596 Clause 11.4)5.14.1.4 Signal or Power FailureIn cases where the operation of retractor depends on anexternal signal or power source, the design shall ensurethat the retractor locks automatically upon failure orinterruption of that signal or power source (ADR Clause4.6.4.4)(AS2596 Clause 11.4)5.14.1.5 Tilt of Emergency Locking RetractorThe design on an ‘Emergency Locking Retractor’ shallensure that it remains unlocked when the vehicle is tiltedup to 12 degrees, longitudinally or transversally, from thehorizontal. (Clause 4.6.4.5) (AS2596 11.6.3 (c)).



Section 5.15



Section 5.15

5.15.1 Analysis of Results (Clause 4.7)After the Seat Belt Assemblies for the front facing Seats has been subjected to the preconditioning and dynamic testsdescribed above they shall not separate within themselves or from any Anchorage. (ADR Clause 4.7.1)The buckle components shall be capable of manual release after the dynamic test. (AS 2596 Clause 14.2)



Section 5.15



5.16 Corrosion Resistance of Metal Parts5.16.1 ProcedureMetal parts or coated metal parts shall be exposed to theASTM B117 salt spray test for 50 hours5.16.2 Analysis of ResultsAfter washing away deposited salt and any corrosionproducts the metal or coated metal parts shall show nosignificant evidence of base metal corrosion or ofblistering of the coating and shall be operational.NOTE “Significant Evidence” means base metalcorrosion, more than 3 mm from an edge or from a linescribed through the coating.(ADR Clause 4.8;) ( AS 2596 Clause 12)5.17 Test on Seat Belt WebbingTests to determine the compliance of the webbing used inseat belts shall be carried out in accordance withAustralian Standard 1753-1983 ‘Webbing for RestrainingDevices for Occupants of Motor Vehicles’.Refer to this standard for webbing requirements and testprocedures.

Tests concerned are5.17.1 Light Degradation Resistance AS 1753 Clause11.2.11.3 (ADR Clause 4.2.7)

5.17.2 Webbing Strength- Dry Breaking LoadAS 1753 Clause 6 (ADR Clause 4.2.7)- Wet Breaking LoadAS1753 Clause 10 (ADR Clause 4.2.7)

5.17.3 Load/Elongation of WebbingAS 1753, (ADR Clause 4.2.7)For calibration of the dummy used on the sled for thedynamic test on a seat belt assembly, webbing is used torestrain the dummy and must meet the followingproperties- Elongation of not less than 12% when subjected to aload of 11 kN using the test procedure specified inAppendix ‘B’ of AS 1753-1983(ADR Clause 4.11.3) (Section 5.15 Dynamic Test)

5.18.2 Locking of Type 4 N Retractors5.18.2.1 Testing EquipmentA suitable apparatus for the tests for locking of Type 4NRetractors is described in Annex E. The design of anysuch test apparatus shall ensure that the requiredacceleration is given at an average rate of increase ofacceleration at least 25 g per second5.18.2.2 Test Procedure5.18.2.2.1 The retractor shall be tested once for lockingwhen the strap has been unwound to full length less300 3 mm5.18.2.2.2 In the case of a retractor actuated by strapmovement, the extraction shall be in the direction inwhich it normally occurs when the retractor is installed ina vehicle5.18.2.2.3 When retractors are being tested for sensitivityto vehicle deceleration they shall be tested at the aboveextraction along two perpendicular axes, which arehorizontal if the retractor is installed in a vehicle asspecified by the safety belt manufacturer. When this

position is not specified, the test facility shall consult thesafety belt manufacturer. One of these axes shall be in thedirection to give the most adverse conditions with respectto actuation of the locking mechanism5.18.2.2.4 To check conformity with the requirements forlocking of the retractor when tilted the retractor shall bemounted on a horizontal table and the table tilted with anangular speed not exceeding 2 degrees per second untillocking has occurred. The test shall be repeated withtilting in other directions to ensure that the requirementsare fulfilled.5.18.2.2.5 The retracting force shall be measured with thesafety belt assembly fitted to dummy as for the dynamictest described in Section 5.18.4. The strap tension shall bemeasured at the point of contact with (but just clear of) thedummy while the strap is being retracted at theapproximate rate of 0.6 metres per minute.5.18.2.3 Analysis of Test Results.Following the tests described above, the Type 4 NRetractor Assembly shall meet the following conditions.5.18.2.3.1 The Retractor locking must have occurredwhen the deceleration of the vehicle reaches 0.85 g5.18.2.3.2 The retractor must not lock for values ofacceleration of the strap measured in the direction of theextraction of the strap of less than 1.0 g.5.18.2.3.3 The retractor must not lock when its sensingdevice is tilted 12 degrees or less in any direction from theinstallation position specified by its manufacturer and5.18.2.3.4 It shall lock when its sensing device is tilted bymore than 40 degrees in any direction from the installationposition specified by its manufacturer.5.18.2.3.5 In cases where the operation of a retractordepends on an external signal or power source, the designshall ensure that the retractor locks automatically uponfailure or interruption of that signal or power source.5.18.2.3.6 A retractor with multiple sensitivity mustsatisfy the requirements above, when tested in accordancewith Section 5.18.2.2 In addition if one of the sensitivitiesrelates to strap extraction, locking must have occurred at astrap acceleration equal to or more than 2.0g measuredalong the line of the extraction of the strap5.18.2.3.7 In the case of the requirements describedabove the amount of strap movement which may occurbefore the retractor locks shall not exceed 50 mm startingat the full length less 500 50 mm. In the case of the testmentioned in Section 5.18.2.3.2 above locking must notoccur during the 50 mm of strap movement starting at thefull length less 500 5 mm (Section 5.18.2.1.1)5.18.2.3.8 If the retractor is part of a lap belt, theretracting force of the strap shall not be less then whenmeasured in the free length between the dummy and theretractor in accordance with Section 5.18.2.5. If theretractor is part of an upper torso restraint, the retractingforce of the strap shall be not less than 2 Nand not more than 7 N when similarly measured. If thestrap passes through a guide or pulley the retractor forceshall be measured in the free length between the dummyand the guide or pulley. If the assembly incorporates adevice that upon manual or automatic operation preventsthe strap from being completely retracted, such as device



shall not be operated when these requirements areassessed.5.18.3 Durability of Retractor Mechanism (ADRAppendix A Clause 7.6)5.18.3.1 Test Equipment. The apparatus for carrying outthe durability of the retractor is shown in Figure 2 ofAnnex D5.18.3.2. Test Procedure, Conditioning5.18.3.2.1 The strap shall be withdrawn and allowed toretract for the required of cycles (40.000 cycles) at a rateof not more than 30 cycles per minute. In the case of‘Type 4N Retractors’ a snatch to lock the retractor shall beintroduced at each fifth cycle.The snatches shall occur in equal numbers at each of fivedifferent extractions, namely, 90, 80, 75, 70 and 65 percent of the total strap remaining wound on the retractor.However, where more than 900 mm is provide the abovepercentages shall be related to the final 900 mm of strapwhich can be withdrawn from the retractor.5.18.3.2.2 The retractor shall then be subjected to thecorrosion tests described in Annex D (AS 2597.9).Preparation and Conditioning of Test Specimen forRetractor Function, Section 6.5.18.3.3 Following the corrosion test the retractor shallthen be subjected to the test for dust resistance. Theapparatus and dust is described in Annex D Section5(C)(d)5.18.4 Dynamic Tests (Clause 4.4.7)Dynamic tests on the seat belt/retractor assembly shall becarried out in accordance with Section 5.15 (AS 2597.13,Determination of Dynamic Performance) including theDynamic Preconditioning and Retractor Durability Test.(Clause 4.7.3 and Clause 4.8)5.18.4.1 Procedure Dust TestThe retractor shall be positioned in the test chamber asdescribed in Annex D. It shall be mounted in anorientation similar to that in which it is mounted in thevehicle. A length of 500 mm of the strap shall be extractedfrom the retractor and kept extracted, except that it shallbe subject to ten complete cycles of retraction andwithdrawal within one or two minutes after each agitationof the dust. For a period of five hours, the dust shall beagitated every twenty minutes for five seconds bycompressed air, free of oil and moisture at a gaugepressure of 5.5 x 105 + 0.5 x 105 Pa entering through anorifice 1.5 0.1 mm in diameter.5.18.4.2 The retractor shall then satisfactorily complete afurther 5,000 cycle (making 45,000 in all)5.18.5 Analysis of Tests Following Conditioning5.18.5.1 Following the above conditioning the retractorshall operate correctly and still meet the requirementsdescribed in Sections 5.18.2.3 after testing to theprocedure described in Section 5.18.2.25.18.7 Dynamic Tests (Clause 4.4.7)Dynamic tests on the seat belt/retractor assembly shall becarried out in accordance with Section 5.15 (AS2597.13,Determination of Dynamic Performance) including theDynamic Preconditioning and Retractor Durability Test(Clause 4.7.3 and Clause 4.8)

6 ORDER OF ACCURACY AND CALIBRATION

6.1 Order of Accuracy. Except where specified inthe ADR or referred documents, the followingorder of accuracy is considered to becommercially achievable and should be taken as aguide. Instrumentation of lesser accuracy isacceptable provided it is taken into account indetermining the certainty of results.The time measurements should be determinedwithin 1% . The order of accuracy of loadmeasurement may vary, depending on the systememployed. In all cases, however, the tests must beconducted with the load reading equaling thecalculated load plus maximum instrument error. Atypical instrument system for load measurementwould have an order of accuracy of 5%.Deflection measurements should be made within3 mm.6.2 Calibration. Routine calibration of load cells,electronic elements and recording equipment is tobe carried out in accordance with Circular 0-12-3.Prior to each series of tests it is desirable that thecomplete load measuring system be calibratedagainst a known standard, e.g. deadweight,universal testing machine or transfer calibrationsystem at a number of points.6.3 Reporting Results. The results of each test areto be recorded in a complete internal report givinga full description of material tested, equipmentused, results and order of accuracy. Forsubmission to the Administrator the determinedresults for loads, deflected position and distortion,are to be recorded together with the internal reportnumber in the appropriate section of the Summaryof Evidence Report. See Section 7.

7 SUMMARY OF EVIDENCE REPORT

The Summary of Evidence Report SE 4/00 is the onlydocument to be sent to the Administrator fordemonstration of compliance to ADR 4/00 or 4/01. Theoriginal test report identification number, the location ofthe test report, the test facility identification number andthe determined results are to be recorded in theappropriate place in the SE 4/00 form for each relevantclause of the ADR.

8 PROCEDURE FOR DESIGNS WITHCERTIFICATION TO ALTERNATIVE STANDARDS

For ADR 4/008.1 The technical requirements of ECE R 16/00 to R16/04 “Safety Belts” shall be deemed to be equivalent tothe technical requirements of ADR 4/00 provided that8.1.1 For ADR Clauses 4.14 to 4.16 for vehicle categoriesMD3, MD4, ME, NB2 and NC non-locking retractorsshall not be employed; and8.1.2 The Light Degradation Resistance of the AustralianStandard 1753 Clause 11.2 and 11.3 and the dust and



precondit ioning (before any dynamic test ing)requirements of AS2597.9 are met:8.1.3 The free end requirements of Clauses 4.3.3.2 or4.16.2 of ADR 4/00 are met (Clause 4.17.1)For ADR 4/018.2 The technical requirements of ECE R 16/04 “SafetyBelts”shall be deemed to be equivalent to the technicalrequirements of ADR 4/01, provided that8.2.1 For ADR Clauses 4.14 to 4.16 for vehicle categoriesMD3, MD4, ME, NB2, and NC non-locking retractorsshall not be employed;.2.2 The Light Degradation Resistance of the AustralianStandard 1753 Clauses 11.2. and 11.3 and the dust andprecondit ioning (before any dynamic test ing)requirements of AS2597.9 are met; and8.2.3 The free end requirements of Clauses 4.3.3.2 or4.16.2 of ADR 4/01 are met.8.3 Seat Belts Assemblies for vehicle category MD3,MD4, ME, NB2 and NC meeting the requirements ofFederal Motor Vehicle Safety Standard No 209, “Seat BeltAssemblies” current as at 13 December 1979 areacceptable except that the use of non-locking retractors asdefined in that Standard shall not be allowed; (Clause4.14.2.4)8.4 Where a Standards Association of Australia (SAA)approval mark and license is held for manufacture of seatbelts to the relevant Australian Standards, relevant partsnoted on the form SE 4/00 shall be completed.In the cases above the relevant parts of form SE 4/00

shall be completed

9 REFERENCES

ADR References

ADR DefinitionsADR 3/00 - Seat AnchoragesADR 4/00 - Seat BeltsADR 4/01 - Seat BeltsADR 5/01/02 - Anchorages for Seat Belts and ChildRestraintsAustralian StandardsAS E35-1970 Pt 1 and Pt 2 -Seat Belt Assemblies forMotor VehiclesAS 2596-1983 - Seat Belt AssembliesAS 1753-1983 Webbing for Restraining Devices forOccupants of Motor VehiclesAS E47-1971 - Webbing for restraining Devices forOccupants of Motor VehiclesAS 2597-1983-Methods of Testing Seat BeltsCircularsCircular 0-12-2 - General Requirements for TestingFacilitiesCircular 0-12-3 - General Requirements for Calibration ofTest Equipment and InstrumentationCircular 0-12-6 - Devices for use in Defining andMeasuring Motor Vehicle Seating AccommodationCircular 0-12-7 - Motor Vehicle Driver’s Eye RangeOther ReferencesASTM B 117 - 1964 Salt spray (fog) TestingFMVSS 209 - December 13 1979 - Seat Belt AssembliesECE R 16/00 to 16/04 - Safety BeltsECE R 14/02 Safety Belt Anchorages



ANNEX A

TEST SEAT AND ANCHORAGES

FOR THE DYNAMIC TEST



ANNEX B

COMPONENT BOUNDARY LOCATION



ANNEX C



ANNEX D



ANNEX D

TO TEST DURABILITY OF RETRACTOR MECHANISM



ANNEX E

DIAGRAM OF AN APPARATUS TO TEST LOCKING OF

EMERGENCY LOCKING ‘TYPE 4N RETRACTORS’

A suitable apparatus is illustrated in the figure and consists of a motor-driven cam, the follower of which is attached bywires to a small trolley mounted on a track. The cam design and motor speed combination is such as to give the requiredacceleration at a rate of increase of acceleration as specified in Section 5.18.3 of the Annex and the stroke is arranged tobe in excess of the maximum permitted webbing movement before locking.On the trolley a carrier is mounted which can be swiveled to enable the retractor to be mounted in varying positionsrelative to the direction of movement of the trolley.When testing retractors for sensitivity to strap movement the retractor is mounted on a suitable fixed bracket and the strapis attached to the trolley.When carrying out the above tests any brackets, etc shall be incorporated in the test installation to simulate as closely aspossible the intended installation in a vehicle.Additional brackets, etc may be required to simulate the installation as intended in the vehicle.



circular 4/01-9-1 test procedures adr 4/01 - …rvcs.infrastructure.gov.au/tfi manual/circular...

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