ADR Compliance Crash Testing Explained Crash testing of an RV1000 Drawer System fitted with Cargo Barrier and Child Restraint mounting points. 5 To better understand what the ADR Ratings mean and how the testing is conducted, we have put together the following information. RV TRADE & FLEET P/L TWIN DRAWER STEEL STORAGE SYSTEM Test to ADR3/02, ADR34/01 & ADR42 210kg CAPACITY Client: Report No: Tested By: Report Date: 18th July 2011 ATSB LN: RV Trade & Fleet P/L P.O BOX 176, GISBORNE, VIC, 3437 RVT&F/DRAWER SYSTEM/01 D.Maigler, Lab Tech. G.Zivkovic MSc,BSc,MIE,MSAE T9868 PAGE 1
1. Introduction Cargo Storage Systems are accessories installed in vehicles to separate cargo from vehicle occupants. This is done not just for a convenience or sudden braking, but more importantly to protect vehicle occupants during a severe collision. Items of load ( cargo ) carried inside vehicle can weight 20-30 times their own static weight during the impact and it is known that is capable inducing severe bodily injuries or even death to the vehicle occupants. 2. Samples Identification RV Trade & Fleet P/L has supplied a twin drawer steel storage system - Drawer System This vehicle storage system has been designed to fit in a variety of 4 wheel drives including station wagons, utes, such as: Toyota Land Cruiser, Prado Nissan Patrol, Pajero etc. The twin drawer Drawer System steel storage system P/N: RV1000. Tare weight 50kg. The storage system has various add ons or optional extras which were provided also for testing. Those include: 1. A partial cargo barrier which can be fitted to the rear of the storage system and to the rear passenger grab handle positions. 2. A twin floor storage platform that fits to the seat mounts of the forward passenger area and to the rear of the storage system. 3. Child restraint points three (3) off which are fitted to the rear of the storage system. The cargo barrier is fixed to the storage system and front twin floor system by the: Brackets are affixed to both using M10 x 1.25mm 8.8 grade bolts using washers and locking nuts. The bottom of the barrier is then affixed to these brackets using M10 x 1.25mm 8.8 grade bolts and nuts. The top of the rear and forward barriers are affixed to a metal plate which has been fitted to the rear and mid passenger grab handle locations using 2x M6 x 1.25mm stainless steel 316 grade set screws for each side. The top cargo barrier mounts / arms are affixed to these plates and the barrier using M10 x 1.5mm 8.8 grade bolts and nuts. The storage system unit (behind the cargo barrier) is bolted onto the vehicle floor using 4x M10 x 1.25mm, 8.8 grade bolts and front cargo storage (behind front cargo barrier) was bolted using 5x M10 x 1.25mm, 8.8 grade bolts. 3. Equipment and Facilities Used 3.1. Sled test facility. 3.2. AD 4321 5t load cell and digital display - to measure test weights. 3.3. Test frame to replace vehicle bodyshell structure. 3.4. ASE crash test facility to SAE J850. 3.5. NAQ DAQ Data Acquisition System. 4. Test Procedure The test procedure used is described below: ADR3 /02 ADR34/01 ADR42/03 Seats and Seat Anchorages - Child Restraint Anchorages Test Child Restraint Anchorages. - This test to be conducted for Type E child restraint for a child weighing from 14kg to 38kg (using an adult lap / sash seat belt and upper anchor point). General Safety Requirements The cargo storage system must restrain specified load without being detached from the vehicle floor, nor to have sharp edges that are likely to increase injuries to the vehicle occupants in the event of an accident. AS/NZS 4034.2:2001 Partial Cargo Barriers for 60 kg capacity. The cargo system to be tested for 60kg cargo barrier capacity, and 150kg cargo restrained by the cargo draws. The total of 210kg of the test load. PAGE 2
5. RVT&F Storage System 210Kg Capacity Impact Test 5.1. RVT&F storage system ready to test. 5.2. RVT&F storage system after the impact test at 49kph. PAGE 3
Cargo Barrier Impact Test to AS 4034.1:2001 Part 2 TEST REPORT B11 Test No: 2139 Date: 20 April 2011 CARGO BARRIER MAKE: RV Trade & Fleet P/L CARGO BARRIER MODEL: Nissan GU Patrol & Toyota LC100 YEAR OF MANUFACTURE: 2011 CARGO BARRIER PRODUCTION DATE: April 2011 TYPE OF IMPACT TEST: Type approval PROCEDURE USED: Horizontal - Full Frontal Sled Test BARRIER POSITION: One position barrier - Rear Barrier MOVABLE SECTION POSITION: N/A IMPACT MASS: 64kg DROP HEIGHT: N/A - Sled test ENERGY DISSIPATION LEVEL: 5,511J IMPACT SPEED: 49kph CARGO BARRIER CAPACITY: 60kg MEASURED DEFORMATION: 72mm < 350mm. EVIDENCE OF FAILURE: N/A RESULT: PASS TESTED BY: G. Zivkovic MSc,BSc,MIEA,MSAE PENETRATION TEST REFERENCE: Mesh TD M/N 222738 & 009484 THIS TEST HAS BEEN CONDUCTED TO AS/NZS 4034.1:2001. PART 2 Cargo Barrier Fig 4.3.1 Test trolley crash pulse. Test speed 49kph PAGE 4
6. Conclusions The Steel Storage System, manufactured by RV Trade & Fleet P/L has been tested (in Toyota LandCruiser 200 Series configuration) for: - 150kg load capacity inside the steel storage drawers + - 3 x 40kg load behind the rear barrier for three (3) child restraint anchorages + - 60kg cargo barrier. Total load of 210kg + 120kg for child restraint anchorages The tests was conducted to confirm the compliance with the following regulations: ADR3 /02 ADR34 /01 ADR42/03 Seats and Seat Anchorages - Child Restraint Anchorages Test Child Restraint Anchorages General Safety Requirements AS/NZS 4034.2:2001 Partial Cargo Barriers for 60 kg capacity. and PASSED all the requirements prescribed by the ADRs and AS/NZS, without any structural weaknesses or degradation of the system to extend that would affect safety of the vehicle occupants or other road users. PAGE 5