shrikant r maratheshrikant r. marathe summit/h25/4. safety_arai... · shrikant r maratheshrikant r....

Shrikant R MaratheShrikant R. MaratheDirector

The Automotive Research Association of India, Pune, India

2nd AAI Summit , Motorcycle Safety SessionDenpasar, Bali, Indonesia

25th November 201325th November 2013

PresentationbyNeelkanth V MaratheNeelkanthV.Marathe

Outline

ARAI ABriefIntroduction

ProfileofIndianTwoWheelerIndustry

TwoWheelerAccidents SomeObservations

T Wh l S f t NTwoWheeler SafetyNorms

Present

Future

Present

Summary

ARAIOverview

Establishment : 1966Location : Pune, INDIA (150 km from Mumbai) Manpower : 575+ Facilities : 12 Laboratories Vehicle Evaluation, Powertrain, Emissions, Facilities : 12 Laboratories Vehicle Evaluation, Powertrain, Emissions,

Safety & Homologation, Passive Safety, Materials, Automotive Electronics, NVH, CAE, Structural Dynamics, Calibration, Post Graduate Academy & Forging Industry Divisiony g g y

Our Offices : China, Korea and ChennaiInvestments : USD $ 60 Million Accreditations ISO 9001 14001 OHSAS 18001 & NABL (ISO 17025)Accreditations : ISO 9001, 14001, OHSAS 18001 & NABL (ISO 17025)

ARAIRoles

Ministry approved test agency to carry out certification testingtesting.

Engaged in sponsored R&D work and development testingtesting.

ARAI is actively engaged inP ti & H i ti f t d d Preparation & Harmonization of standards.

Secretariat for AISC and CMVR-TSC. Deliberation of policy matters affecting Auto R&D. Creation of facilities and building up competence

by undertaking forward looking research &technology demonstration projects.

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2nd largestintheworldl h 90%arelessthan125cc.

Maximumoperatingspeedrangefrom5070km/h.duetotrafficconditions

DesignedtobeFuelefficientandLowemissiongcompliant.

Two wheeler market in India is highly priceTwowheelermarketinIndiaishighlypricesensitive.

In the existing scenario Indian vehicles are Intheexistingscenario,IndianvehiclesaremeetingthecurrentECErequirements


2nd largest2Wmanufacturerintheworld

20%2Wvehiclesuselessthan125ccengine

Maximum operating speed range from 50 to 70 kmphMaximumoperatingspeedrangefrom50to70kmphduetoinherenttrafficconditions

Designedtobefuelefficientandlowemissioncompliant

2WmarketinIndiaishighlypricesensitive

I th t i I di 2W hi l ti Inthecurrentscenario,Indian2WvehiclesaremeetingECErequirements

Automotive2wheelerindustryClustersinIndia

D lhi G N id

HeroMotorCorporationHondaMotorcyclesand

ScootersLtd.,L hi M hi Ltd

North / Central- Delhi-Gurgaon-Faridabad

Delhi-Gurgaon-Noida-Ghaziabad

Ludhiana Haridwar

LohiaMachinesLtd.,SuzukiMotorcyclesLtd.,YamahaMotorIndiaBMWMotorcyclesIndiaTriumph India

Kolkata

Jamshedpur

Rajkot-Halol

Pitampur TriumphIndia

BajajAutoLtd.,Mahindra&MahindraLtd.,

West- Mumbai-Pune-Nasik-Aurangabad

Mumbai-Pune-NasikAurangabad Hyderabad

DSK HyosungLtd.,PiaggioVehicles(Vespa)

South- Chennai - Bangalore-Hosur

Chennai Bangalore HosurRoyal Enfield Motors Ltd.,TVS Motors Ltd.,

g

GrowthdriversfortheIndianAutomotiveIndustry

GovernmentOveralleconomic

Policies growth

Contemporaryproducts

GrowthinIncomelevelsNew

d t Indian AutomotiveIncreasing

Shorterlifecycle Easier

financing

productlaunches

IndianAutomotiveIndustry

consumerdemand

ExportCompetitiveness

d d CostCompetitiveness

Reducedcosttoconsumer

Indiaemergingasaf t i h bmanufacturinghub

AttractivenessoftheIndianAutomotiveindustry

Large and growing domestic demand Demand growth expected to be

around

Export Potential Increased outsourcing has

led to a large potential toaround 10 % CAGR making India one of the fastest growing markets

led to a large potential to export components and vehicles to other markets

Proven product Development capabilities

Capabilities to develop complete vehicles and systems

High quality standards 12 Indian component Indian Autovehicles and systems

Several global auto companies have R&D centres in India

Companies can leverage Indias

pmanufacturers have won the Deming Prize for quality

Most leading component manufacturers are QS and

IndianAutoIndustry

p gacknowledged leadership in the IT industry

Stable economic policies Competitive manufacturing t

ISO certified

p Continuity in reforms and policies India targets to emerge as the manufacturing hubfor small cars

costImplementation of VAT, has positioned India as one of the leading low cost

f t imanufacturing sources

2WheelerMarketinIndia

Domestic volume growth has been strong over the past five yearsDomesticvolumegrowthhasbeenstrongoverthepastfiveyearsgrowingatabout11%CAGR

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MotorCycleAccidentsintheworld Concerns

Threemajorcausesofhumancasualtiesin2020asforecastedwouldbeo Heart diseaseo Major depressiono Road traffic accidents**

C tl 1 illi l di i d id t B 2020 thi fi ill i t 2 Currently over 1 million people die in road accidents. By 2020 this figure will rise to 2million. 75% of victims are pedestrians and two wheeler users.

85% of accidents happening worldwide occur in developing countries.pp g p g

Three fourths of registered vehicles in India are motorized twowheelers.

Two wheeler riders and pillion were the second leading road user category for bothdeaths (38%) and injuries (51%).

Three fourths (87%) were amongst men.

Brain and limb injuries were more frequent in this group.

More than half (both fatal and non fatal injuries) had not worn helmets.

**According to an independent study by WHO

2WheelerAccidents FatalInjuries Analysis

Nearly three fourths of fatal and 82% of the non fatal two wheeler injuriesoccur in the age group of 16 45 years with majority of them in 20 30 years.

Three fourths (87%) of both fatal and nonfatal injuries in two wheeler ridersoccur among men.

Women in < 15 yrs. and > 40 yrs. are involved in road crashes

More than half the deaths among two wheeler riders and pillions occur

2WheelerCollisionPattern

Morethanhalfthedeathsamongtwo wheelerridersandpillionsoccurduetocollisionwithtrucks(32%)andbuses(23%).

Injuries are severe in these crashes and hence, deaths are higher.Injuriesaresevereinthesecrashesandhence,deathsarehigher.

Othertwowheeler(28%)andcars(8%)collidewiththevehicleofinjuredpersoninonefourthofcrashes.

Rearendcollisions(40%)(withmajorityofroadsbecomingoneways),sideanglecollisions(15%),headoncollisions(13%)andskidandfall(12%)wereth lli i ttthecommoncollisionpatterns.

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TrendsinAutoregulations SafetyandEnvironmentrelated..

Approach Regulation Road Map Targets pp Harmonization with ECE

standards More Homologation and

Industry challenges to development

Better vehicles: safer and

2009200820062004 200 72005 2013

gCertification testing agencies and centres

more environment friendly

200820062004 20072005

Status of Indian Regulations Number ofIndian automotive regulations are technically aligned to the ECE regulations. The table on the right

StatusofIndianRegulations NumberofRegulations

Technically aligned 101P ti l l l li t 11shows the level of technical

alignment of the Indian regulations with the ECE regulations

Partial level alignment 11Items/Regulationstobecovered

19

T t l 3Total 131

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Safety norms at present - Vehicle level

Anautomobilehasmoreweightandbulkthanamotorcycle. Ithasdoorbeamsandarooftoprovidesomemeasureofprotectionfrom

impact or rollover It has cushioning and airbags to soften impact and safetyimpactorrollover.Ithascushioningandairbagstosoftenimpactandsafetybeltstoholdpassengersintheirseats.

Ithaswindshieldwashersandwiperstoassistvisibilityintherainandsnow.A bil h bili b i ' f h l d bAnautomobilehasmorestabilitybecauseit'sonfourwheels,andbecauseofitssize,itiseasiertosee.

Amotorcyclesuffersincomparisonwhenconsideringvehiclecharacteristicsthatdirectlycontributetooccupantsafety.Wh l ifi i i h b lk d h Whatamotorcyclesacrificesinweight,bulk,andothercrashworthinesscharacteristicsissomewhatoffsetbyitsagility,manoeuvrability ability to stop quickly and ability to swervemanoeuvrability,abilitytostopquickly,andabilitytoswervequicklywhennecessary.

Safety norms at present - Vehicle level

Axlereactions

STANDARD IS:118251986

Motorcycles are weighed withoutMotorcyclesareweighedwithoutanyhumaninterventiontophysicallysupportthevehicleonweightmeasurementpads.

Measurements are made with a Measurementsaremadewithaaccuracyof1%ofmeasuredvalue.

Speedometercalibration

STANDARD IS11827 2008

Motorcyclesequippedwithadigitaloranaloguespeedometer

lib t d (V) t d ( ) farecalibrated(V)atspeeds(v)of40kmph,80kmphand80%ofmaximum designed speed.maximumdesignedspeed.

Errormeasuredshouldbewithin0 1 V 8 k h0.1V+8kmph

TestprocedurearealignedwithUNR39

Gradeability Performance

STANDARD AIS003,IS:139882002

Statutorylimitforgradeabilityis7degreesintheforwarddrivingdirection.

Thevehicleischeckedforitsstopstart performance.startperformance.

PassbyNoiseLevel


Noise produced by the motorcycleNoiseproducedbythemotorcycleismeasuredduringaccelerationwithaapproachspeedinrelevantgearsattwothirdofenginerpmproducingmaximumpowerinastretch of 20mstretchof20m.

The Noise level should not exceedTheNoiselevelshouldnotexceed80dB(A)

TestprocedureandnoiselimitsalignedwithUNR41

FoundationBrakeTest


Twowheelersaretestedfortheirstoppingdistanceanddecelerationperformancesin both laden and lightly loadedinbothladenandlightlyloadedconditionsathighspeeds,withwetandhotbrakesforbothfrontandrearbrakesindividually.

d l d h TestprocedureisalignedwithUNR78

ABSTest


ABSON SpeedStops on high friction surface 60 Km/h

Surface PeakBrakingCoefficientStopsonhighfrictionsurface 60Km/h

Stopsonlowfrictionsurface 60Km/hWheelLockcheckonhighandLowfriction 80Km/hWheelLockcheckHightolowfrictionsurfacetransit 50Km/h

LowFriction 0.9

WheelLockcheckLowtoHighfrictionsurfacetransit 50Km/hABSOFF

StopswithanABSElectricalFailure 60Km/h

TestprocedureisalignedwithUNR78

TellTalesandControls

STANDARD AIS071PART1&2

Alltelltales,indicatorsontheinstrumentpanelarecheckedforillumination,colourandproperfunctioning.

The symbols on the tell tales, controls andThesymbolsonthetelltales,controlsandindicatorsareverifiedasmentionedinthestandard.

Functioningofallthecontrolsarealsoverified

Req irements ha e been aligned ith UN R60 RequirementshavebeenalignedwithUNR60

RearProtectionDevice

STANDARD CMVR#123

AllMotorcyclesshouldbeequippedwithrearprotectiondevicecoveringh lf th h lhalfthewheel.

It should prevent the intervention ofItshouldpreventtheinterventionoflooseclothesofpillionriderintothewheel.

ElectromagneticInterference

STANDARD AIS004PART1

Requirements have been aligned with UN R10 RequirementshavebeenalignedwithUNR10

PillionHandHoldTest

STANDARD IS:14495 Strengthrequirementsofpillionstrapsandhandholdsarechecked.

Thestrapsanditsattachmentshallwithstandaverticaltractionforceof200kgappliedstaticallytothecenterofthesurfaceatamaximumpressuref 2 i h iof2MPa,withoutsnapping.

Thetwohandgripsshouldbemountedoneoneachsidesymmetricalmannerwhichshallwithstandaverticaltractionforce of 100 kg applied statically to theforceof100kgappliedstaticallytothecenterofthesurfaceatamaximumpressureof1MPa,withoutsnapping.p , pp g

Horninstallation

STANDARD AIS014:2001 Soundpressurelevelemittedbythedevice(s)fittedonthevehicleshallbemeasuredatadistanceof7minfrontofthevehicle.Themaximumsound pressure level shall be soughtsoundpressurelevelshallbesoughtwithintherangeof0.5and1.5mabove the ground.abovetheground.

MaximumSoundPressureLevelmeasured on 2 Wheelers of a powermeasuredon2Wheelersofapowerlessthan7kWisbetween83dB(A)to112dB(A)


Installationrequirementsofrearviewmirror

STANDARD AIS002 Installation requirements cover, Generalrequirements Position requirementsrequirements , Position requirements ,Adjustment requirements, Field of visions.

For 2 wheelers above 70cc shall have For 2 wheelers above 70cc shall have2 mirror on LH and RH side and for2 wheelers below 70 cc shall have oneee e s be o 0 cc s a a e o emirror on one side.

When vehicle is tested at about 80% ofWhen vehicle is tested at about 80% ofmax speed on test track for 10 min , themirror shall not show move significantly tochange the field of view.

Test procedure is aligned with UN R46

Safetycriticalcomponentsfortwowheelers

Lighting &

Signaling Tyres

Wheel rim

Brake Fluid

Signaling devices

Rear B k eaView Mirror

Brake Hoses

Metallic F l

Plastic Fuel Tank

Horn Fuel Tank

Tank

AutomotiveHorn(AudibleWarningDevice)

STANDARD IS1884:1993 Thesetestsarebasicallyrequiredtocheck,FunctionalPerformance,Reliability,Quality,etc.

In an open space of radius 12m in which Inanopenspaceofradius12minwhichtherearenoobstaclesinbetween,withbackground noise at least 10 dB belowbackgroundnoiseatleast10dBbelowthatproducedbyhornsundertest,andthehorntobemounted1.2mabovegroundanddirectedhorizontallytomicrophoneofsoundlevelmeteratadistance of 2m from front of the horndistanceof2mfromfrontofthehorn

TestprocedureisalignedwithUNR28Test procedure is aligned with UN R 8

Rearviewmirror

STANDARD AIS001 Rearviewmirrorsarecheckedfor

Performancerequirements,MechanicalBehaviour,EnvironmentalPerformancetest

Performancerequirements Radiusofcurvatureanddimensions. Reflectivity Reflectivity Distortionfactor Mechanicalbehavior Impact test Impacttest Bendingtest Vibrationtest

E i t l f t t Environmentalperformancetest TemperatureresistanceMoistureresistancetest SaltspraytestWeatherresistancetest TestprocedureisalignedwithUNR46

Lightingandlight signalling devices

STANDARD AIS:010

TestprocedureisalignedwithUNR74p g

Hydraulicbrakehoses

STANDARD IS : 7079 1995Testsconducted

ConstrictionTest Expansion test Expansiontest Pressuretest Burstingstrengthtest

Whip, Burst & expansion T t i

g g WhipTest TensileTest

Test rig SaltSpraytest Coldbendtest Ozone resistance test Ozoneresistancetest HotImpulsetest BrakeFluidcompatibilityTestp y

Fueltank(MetallicandPlastic)

STANDARD IS14681 METALLICFUELTANKTestconductedLeakageTest Ordinaryposition/upsideposition 50gms/min.

PressureTestShouldwithstandpressureof130kPaabsolutewithoutleakage.Testprocedureisalignedwith70/221/EECPLASTICFUELTANKTestsconductedCorrosiontestOverturntestFuelpermeabilitytestMechanical Strength TestMechanicalStrengthTestImpactresistancetestFireresistancetestResistancetoHightemperatureTestprocedureisalignedwithUNR34

Tyre test

STANDARD IS15627

TestsconductedDynamicgrowthtestE d TEnduranceTest

Load/SpeedPerformanceTestTyre Strength Test

Plungertest

TyreStrengthTestBeadUnseatingResistanceTestDynamicgrowthtest


Endurance testEndurancetest

Wheelrimtest

STANDARD AIS073PART1,2&3

Following tests are conducted on wheel rims (Light Alloy Wheel Rims, Sheet MetalWheel Rims, Spoke Wheel Rims

TorsionMomentTestSystem RadialImpactResistanceTest Deflectiontest Airleaktest

Torsion testC i t tImpact test TorsiontestCorneringtestImpacttest

SPRAYSUPPRESSIONTEST

STANDARD AIS103

Thisstandardsisapplicabletobikeswithenginedisplacementvolume

th 200morethan200cc.

Requirement:Requirement:

Widthnotlessthanthetyreoverallwidth,upto45degreesofwheelcoverageangleandwidthshallbelessth h lf f th t ll idth tthanhalfofthetyreoverallwidthat60degreesofwheelcoverageangle.

Twowheelerelectricvehicles

Standard BriefRequirements

AIS038(ECER 100 ) Construction & Functional Safety ( ) yBattery mounting, ventilation, creepagedistance, insulation resistance,protection against electric shock, onboard charger, water effects testsg ,(washing, flooding, heavy rainstorm)

AIS039(ECER101) Measurement of electrical energyconsumption

AIS040(ECER101) Measurement of electrical range

AIS041(ECER101) Measurement of net power, max. 30min powermin power

AIS048(USABCEVBatteryTestProceduresManual)

Safety Requirements for TractionBatteries Electrical & MechanicalAbuse Tests

AIS049 Type Approval of Electric Vehicles Brake performance, grade ability, passby noise level, EMI, wiper, lightingsystem, safety belt, steering column,dashboard etc.

Emissiontest

STANDARD AsperRule115ofCentralMotorVehicleRules

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DaytimeRunningLamp(DRL)

Daytimerunninglamp"meansalampfacinginaforwarddirectionusedtomakethevehiclemoreeasilyvisiblewhendrivingduringdaytimeDRL reduce daytime accidents by making vehicles more conspicuous to other roadDRL reducedaytimeaccidentsbymakingvehiclesmoreconspicuoustootherroadusers DRLsprovidenotonlyimprovedvisibility(detection)butalsoimprovedreactiontimesandestimationofspeedanddistancepInadditiontoincreasingthedistanceatwhichvehiclescouldbereliablydetected,DRLsmakevehiclesappearcloser.Thismakesdriversmorelikelytorejectshortgapsforapotentiallyhazardousmanoeuvre.p y

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HIDheadlampsonmotorcycles

Givesthesameilluminationforasmallerelectricalsupply

Colour temperature is similar to day lightColourtemperatureissimilartodaylightIncreaseseffectivenighttimevision,foraconstantgeneratoroutput

This provides a great potential for developing newThisprovidesagreatpotentialfordevelopingnewlightingsystemswithgreaterandmorereliableperformancethroughoutthemotorcyclerange

47

Horizontalinclinationadjustmentsystem(HIAS)

HISA means a device that adjusts the horizontal inclination of theheadlamp towards zero

Headlamp visibility is improved by compensating the headlamp banklangle in curves.

During the curves, the oncoming vehicle driver receives no glare whenthe headlamp bank angle is compensated to the same level as the vehicleb d b k l

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body bank angle

Emissionnorms BSIV(Future)

TwoWheelerElectricVehicles(futureareas)

EMCevaluationofelectrictwowheelers

Electricalsafetyrequirements

BMSdevelopmentforLiIonbatteries

Charginginfrastructure

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Summary

Formulating Road safety policies with a focus on safety oftwo-wheeler riders and pillions.two wheeler riders and pillions.

Scientific design and maintenance of roads with speedcontrol mechanisms.control mechanisms.

Separating two-wheelers and other slow moving trafficfrom heavy and speeding vehicles (on all possible roads).from heavy and speeding vehicles (on all possible roads).

Strict enforcement of traffic regulations and focused speedcontrol mechanisms.control mechanisms.

Summary Control of drinking and driving.

Strict driver licensing mechanisms and systems (graduateddriver licensing systems are found to give benefits).

Mandatory helmet legislation and enforcement.

Design of Safer vehicles Increasing visibility of two wheeler Design of Safer vehicles, Increasing visibility of two wheelerriders and pillions (bright colored helmets, use of reflectivematerials, etc.).

Improved trauma care practices.

Increasing research to understand situation,circumstances, characteristics and risk factors of two-wheeler crasheswheeler crashes.

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