Directive 2005/66/EC of the European Parliament and of the Council (repealed)Show full title

ANNEX I TECHNICAL PROVISIONS

1. DEFINITIONS

For the purposes of this Directive the following definitions shall apply:

1.1. ‘Vehicle type’ means a category of motor vehicle which, forward of the A-pillars, does not differ in such essential respects as:

(a)

the structure,

(b)

the main dimensions,

(c)

the materials of the outer surfaces of the vehicle,

(d)

the component arrangement (external or internal),

(e)

the method of fixing a frontal protection system,

in so far as they may be considered to have an effect on the validity of the results of the impact tests prescribed in this Directive.

For the purposes of frontal protection systems to be type-approved as separate technical units, any reference to vehicle may be interpreted as referring to the frame on which the system is mounted for testing and which is intended to represent the front end outer dimensions of the particular vehicle type for which the system is being type-approved;

1.2. ‘normal ride attitude’ means the vehicle attitude in running order, positioned on the ground, with the tyres inflated to the recommended pressures and the front wheels in the straight-ahead position, with maximum capacity of all fluids necessary for operation of the vehicle, with all standard equipment as provided by the vehicle manufacturer, with a 75 kg mass placed on the driver's seat and a 75 kg mass placed on the front passenger's seat and with the suspension set for a driving speed of 40 km/h or 35 km/h in normal running conditions specified by the manufacturer (especially for vehicles with an active suspension or a device for automatic levelling);

1.3. ‘external surface’ means the outside of the vehicle, forward of the A-pillars, including the bonnet, the wings, the lighting and light-signalling devices and the visible strengthening components;

1.4. ‘radius of curvature’ means the radius of the arc of a circle which comes closest to the rounded form of the component under consideration;

1.5. ‘extreme outer edge’ of the vehicle means, in relation to the sides of the vehicle, the plane parallel to the median longitudinal plane of the vehicle coinciding with its outer lateral edge, and, in relation to the front and rear ends, the perpendicular transverse plane of the vehicle coinciding with its outer front and rear edges, account not being taken of the projection:

(a)

of tyres near their point of contact with the ground, and connections for tyre pressure gauges;

(b)

of any anti-skid devices which may be mounted on the wheels;

(c)

of rear-view mirrors;

(d)

of side direction indicator lamps, end outline marker lamps, front and rear position (side) lamps and parking lamps;

(e)

in relation to the front and rear ends, of parts mounted on the bumpers, of towing devices and of exhaust pipes;

1.6. ‘bumper’ means the front, lower, outer structure of the vehicle as type-approved. It includes all structures of the vehicle that are intended to give protection to the vehicle when involved in a low speed frontal collision with another vehicle and also any attachments, such as registration fixing plates, to this structure. It does not include equipment which is fitted to the vehicle following type-approval and intended to provide additional frontal protection for the vehicle;

1.7. ‘frontal protection system’ means a separate structure or structures, such as a bull bar or a supplementary bumper, which is intended to protect the external surface of the vehicle, above and/or below the original-equipment bumper, from damage in the event of a collision with an object. Structures, with a maximum mass of less than 0,5 kg, intended to protect only the lights, are excluded from this definition;

1.8. ‘bonnet leading edge reference line’ means the geometric trace of the points of contact between a straight edge 1 000 mm long and the front surface of the bonnet, when the straight edge, held parallel to the vertical longitudinal plane of the car and inclined rearwards by 50° and with the lower end 600 mm above the ground, is traversed across and in contact with the bonnet leading edge. For vehicles having the bonnet top surface inclined at essentially 50°, so that the straight edge makes a continuous contact or multiple contacts rather than a point contact, the reference line is determined with the straight edge inclined rearwards at an angle of 40°. For vehicles of such shape that the bottom end of the straight edge makes first contact, then that contact is taken to be the bonnet leading edge reference line, at that lateral position. For vehicles of such shape that the top end of the straight edge makes first contact, then the geometric trace of 1 000 mm wrap around distance as defined in paragraph 1.13 will be used as the bonnet leading edge reference line at that lateral position. The top edge of the bumper shall also be regarded as the bonnet leading edge for the purposes of this Directive, if it is touched by the straight edge during this procedure;

1.9. ‘upper frontal protection system reference line’ means the upper limit to significant points of pedestrian contact with the frontal protection system or the vehicle. It is the geometric trace of the uppermost points of contact between a straight edge 700 mm long and the frontal protection system or the vehicle front (whichever is touched), when the straight edge, held parallel to the vertical longitudinal plane of the vehicle and inclined rearwards by 20°, is traversed across the front of the vehicle, while maintaining contact with the ground and with the surface of the frontal protection system or vehicle;

1.10. ‘lower frontal protection system reference line’ means the lower limit to significant points of pedestrian contact with the frontal protection system or the vehicle. It is the geometric trace of the lowermost points of contact between a straight edge 700 mm long and the frontal protection system, when the straight edge, held parallel to the vertical longitudinal plane of the vehicle and inclined forwards by 25°, is traversed across the front of the vehicle, while maintaining contact with the ground and with the surface of the frontal protection system or the vehicle;

1.11. ‘upper frontal protection system height’ means the vertical distance between the ground and the upper frontal protection system reference line, defined in paragraph 1.9 with the vehicle positioned in its normal ride attitude.

1.12. ‘lower frontal protection system height’ means the vertical distance between the ground and the lower frontal protection system reference line, defined in paragraph 1.10 with the vehicle positioned in its normal ride attitude;

1.13. ‘1 000 mm wrap around distance’ means the geometric trace described on the frontal upper surface by one end of a 1 000 mm long flexible tape, when it is held in a vertical fore and aft plane of the car and traversed across the front of the bonnet bumper and frontal protection system. The tape is held taut throughout the operation with one end held in contact with the ground, vertically below the front face of the bumper and the other end held in contact with the frontal upper surface. The vehicle is positioned in the normal ride attitude;

1.14. ‘frontal protection system leading edge reference line’ means the geometric trace of the points of contact between a straight edge 1 000 mm long and the front surface of the frontal protection system, when the straight edge, held parallel to the vertical longitudinal plane of the car and inclined rearwards by 50°, is traversed across and in contact with the frontal protection system leading edge. For vehicles having the frontal protection system top surface inclined at essentially 50°, so that the straight edge makes a continuous contact or multiple contacts rather than a point contact, the reference line is determined with the straight edge inclined rearwards at an angle of 40°;

1.15. ‘Head performance criterion (HPC)’ shall be calculated using the expression:

where ‘a’ is the resultant acceleration at the centre of gravity of the head (m/s² as a multiple of ‘g’, recorded versus time and filtered at a channel frequency class 1 000 Hz; t₁ and t₂ are two times defining the beginning and the end of the relevant recording period for which the value of HPC is a maximum between the first and last instants of contact. Values of HPC for which the time interval (t₁ - t₂) is greater than 15 ms are ignored for the purposes of calculating the maximum value.

2. CONSTRUCTION AND INSTALLATION PROVISIONS

2.1. Frontal protection systems

The following requirements apply equally to frontal protection systems as supplied fitted to new vehicles and to frontal protection systems supplied as separate technical units for fitting to specified vehicles.

However, with the agreement of the competent approval authority, the requirements contained in paragraph 3 can be considered to have been satisfied wholly or in part by any equivalent testing carried out on the frontal protection system pursuant to another type-approval directive.

2.1.1. The components of the frontal protection system shall be so designed that all rigid surfaces which can be contacted by a 100 mm sphere, have a minimum radius of curvature of 5 mm.

2.1.2. The total mass of the frontal protection system, including all brackets and fixings, shall not exceed 1,2 % of the mass of the vehicle for which it is designed, subject to a maximum of 18 kg.

2.1.3. The height of the frontal protection system, when fitted to a vehicle, shall be no more than 50 mm higher at any point than the bonnet leading edge reference line, as defined in paragraph 1.8, measured on a vertical longitudinal plane through the vehicle at that point.

2.1.4. The frontal protection system shall not increase the width of the vehicle to which it is fitted. If the overall width of the frontal protection system is more than 75 % of the width of the vehicle, the ends of the system shall be turned in towards the external surface in order to minimise the risk of fouling. This requirement is considered to be satisfied if either the frontal protection system is recessed or integrated within the bodywork or the end of the system is turned so that it is not contactable by a 100 mm sphere and the gap between the end of the system and the surrounding bodywork does not exceed 20 mm.

2.1.5. Subject to paragraph 2.1.4, the gap between the components of the frontal protection system and the underlying external surface shall not exceed 80 mm. Local discontinuities in the general contour of the underlying body (such as apertures in grilles, air intakes, etc.) shall be ignored.

2.1.6. At any lateral position across the vehicle, in order to preserve the benefits of the vehicle bumper, the longitudinal distance between the most forward part of the bumper and the most forward part of the frontal protection system shall not exceed 50 mm.

2.1.7. The frontal protection system shall not reduce significantly the effectiveness of the bumper. This requirement shall be considered to be satisfied if there are no more than two vertical components and no horizontal components of the frontal protection system overlapping the bumper.

2.1.8. The frontal protection system shall not be inclined forward of the vertical. The top parts of the frontal protection system shall not extend upwards or rearwards (towards the windscreen) more than 50 mm from the bonnet leading edge reference line of the vehicle, as defined in paragraph 1.8, with the frontal protection system removed. Each point of measurement is made on a vertical longitudinal plane through the vehicle through that point.

2.1.9. Conformity with the requirements of other vehicle type-approval directives shall not be compromised by the fitting of a frontal protection system.

2.2. Frontal protection systems that are separate technical units may not be distributed, offered for sale or sold unless accompanied by a list of vehicle types for which the frontal protection system is type approved and clear assembly instructions. The assembly instructions shall contain specific instructions on installation including fixing modes for the vehicles for which the unit has been approved and to enable the approved components to be mounted on that vehicle in a manner that complies with the relevant provisions of paragraph 2.1.

3. TEST PROVISIONS

3.1. In order to be approved, frontal protection systems must pass the following tests:

3.1.1. Lower Legform to Frontal Protection System. The test is performed at an impact speed of 40 km/h. The maximum dynamic knee bending angle shall not exceed 21,0°, the maximum dynamic knee shearing displacement shall not exceed 6,0 mm, and the acceleration measured at the upper end of the tibia shall not exceed 200 g.

3.1.1.1. However, with respect to frontal protection systems approved as separate technical units for use only on specified vehicles of total permissible mass not exceeding 2,5 tonnes which have been type approved before 1 October 2005, or vehicles of total permissible mass exceeding 2,5 tonnes, the provisions of paragraph 3.1.1 may be replaced by the provisions of either paragraph 3.1.1.1.1 or paragraph 3.1.1.1.2.

3.1.1.1.1. The test is performed at an impact speed of 40 km/h. The maximum dynamic knee bending angle shall not exceed 26,0°, the maximum dynamic knee shearing displacement shall not exceed 7,5 mm, and the acceleration measured at the upper end of the tibia shall not exceed 250 g.

3.1.1.1.2. Tests are performed on the vehicle with the frontal protection system fitted and without the frontal protection system fitted at an impact speed of 40 km/h. The two tests shall be performed in equivalent locations as agreed with the relevant test authority. The values for the maximum dynamic knee bending angle, the maximum dynamic knee shearing displacement and the acceleration measured at the upper end of the tibia shall be recorded. In each case the value recorded for the vehicle fitted with the frontal protection system shall not exceed 90 % of the value recorded for the vehicle without the frontal protection system fitted.

3.1.1.2. If the lower frontal protection system height is greater than 500 mm this test must be replaced by the Upper Legform to Frontal Protection System test, as specified in paragraph 3.1.2.

3.1.2. Upper Legform to Frontal Protection System. The test is performed at an impact speed of 40 km/h. The instantaneous sum of the impact forces with respect to time shall not exceed 7,5 kN and the bending moment on the test impactor shall not exceed 510 Nm.

The Upper Legform to Frontal Protection System test shall be carried out if the lower frontal protection system height at the test position is more than 500 mm.

3.1.2.1. However, with respect to frontal protection systems approved as separate technical units for use only on specified vehicles of total permissible mass not exceeding 2,5 tonnes which have been type approved before 1 October 2005, or vehicles of total permissible mass exceeding 2,5 tonnes, the provisions of paragraph 3.1.2 may be replaced by the provisions of either paragraph 3.1.2.1.1 or paragraph 3.1.2.1.2.

3.1.2.1.1. The test is performed at an impact speed of 40 km/h. The instantaneous sum of the impact forces with respect to time shall not exceed 9,4 kN and the bending moment on the test impactor shall not exceed 640 Nm.

3.1.2.1.2. Tests are performed on the vehicle with the frontal protection system fitted and without the frontal protection system fitted at an impact speed of 40 km/h. The two tests shall be performed in equivalent locations as agreed with the relevant test authority. The values for the instantaneous sum of the impact forces and the bending moment on the test impactor shall be recorded. In each case the value recorded for the vehicle fitted with the frontal protection system shall not exceed 90 % of the value recorded for the vehicle without the frontal protection system fitted.

3.1.2.2. If the lower frontal protection system height is less than 500 mm this test is not required.

3.1.3. Upper Legform to Frontal Protection System Leading Edge. The test is performed at an impact speed of up to 40 km/h. The instantaneous sum of the impact forces with respect to time, to the top and the bottom of the impactor, should not exceed a possible target of 5,0 kN and the bending moment on the impactor should not exceed a possible target of 300 Nm. Both results shall be recorded for monitoring purposes only.

3.1.4. Child/Small Adult Headform to Frontal Protection System. The test is performed at an impact speed of 35 km/h using a 3,5 kg headform test impactor for the child/small adult. The headform performance criterion (HPC), calculated from the resultant of the accelerometer time histories, in accordance with paragraph 1.15, shall not exceed 1 000 in all cases.