H:Abteilungs%20ArchivEmpfehlungenEUWA std 405 - VDA - Standardised packa… · The VDA...

April 2001

SPECIFICATIONS CONCERNANT LE SYSTEME STANDARD DE PALETTES POUR ROUES DE VEHICULES TOURISME ET DE POIDS LOURDS

PFLICHTENHEFT FÜR EIN LADUNGSTRÄGERSYSTEM ZUR EINHEITLICHEN VERPACUNG VON PKW-UND LKW-SCHEIBENRÄDERN

EWPS Wheel pallet

EUROPEAN WHEEL PALLET SYSTEM

This paper has been designed to provide a standard load carrier system consisting of base pallets, top frames, and separators in order to ensure standardised transportation of car and truck wheels made of steel and light alloy; a system that should be employed by all vehicle and wheel manufacturers.

Substantial technical details have been worked out by the "Ad Hoc Work Shop Wheel Packaging" of the VDA, the German Verband der Automobilindustrie e.V. in 60079 Frankfurt, and the "Logistic Commission" of the European Wheel Association (EUWA)

VDA Ad Hoc Work Shop Wheel Pallet

AI-KO Enzler, AUDI, BMW, Durotherm, Ford, Lemmerz, Daimler-Benz, Adam Opel, Pebra, Porsche, Mannesmann Kronprinz, Südrad, Volkswagen and the "Logistic Commission" of the European Wheel Association

Publisher: Verband der Automobilindustrie All rights reserved. No part of Westendstraße 61 this publication may be Postfach 17 05 63 reproduced in any form or by Kennwort: VDA-AKVD 4503 any means without prior 60079 Frankfurt permission of the publishers. Telefon 069/97507-283 Telefax 069/97507-300

STANDARDISED PACKAGING OF CAR AND TRUCK WHEELS

ES

4.05

Seite 1 von 29EUWA_std_405

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CONTENTS

1 INTRODUCTION

2 OBJECTIVES

3 SYSTEM COMPONENTS

4 HANDLING

5 IDENTIFICATION, COLOUR CODING

5.1 Type Designations

5.2 Identification Aid

6 GENERAL REQUIREMENTS

7 BASE PALLET AND TOP FRAME REQUIREMENTS

7.1 Dimensions

7.2 Weight and Load

7.3 Deflection

7.4 Marking

7.5 Materials Handling Technology

7.6 Storage Technology

7.7 System Features

7.8 Environment

7.9 Material

8 SEPARATORS REQUIREMENTS

8.1 General Requirements

8.2 Design

8.3 Environment

8.4 Material



9 EXEMPT FROM PATENT AND TRADE MARK RIGHTS

10 ECONOMIC efficiency

11 OPERATING CONDITIONS, TRAFFIC AND, EXCHANGE

11.1 "User Pool"

11.2 Traffic and Exchange

11.3 Quality Assurance and Quality Control

11.4 Transaction

11.5 Approval

11.6 Series Control/Quality Control

11.7 Performance Checks/Functional Testing

11.8 Alterations

12 CONDITIONS OF QUALITY CONTROL

12.1 Area of Application

12.2 Quality Requirements

13 USE AND MAINTENANCE

APPENDIX

Appendix 1 Components

Page 1-2 Type Designations and Dimensions

Page 2-2 Type Designations, Abbreviations

Appendix 2 Checks Required for Base Pallet and Top Frame Licensing

Appendix 3 Checks Required for Plastic Separator Licensing

Appendix 4 Damage List Base Pallet and Top Frame



Appendix 5 Damage List Separators

Appendix 6 General Technical Data Separators

Page 1-3 EWPS Wheel Pallet, Technical data of sheets for separators for steel wheels

Page 2-3 EWPS Wheel Pallet, Technical data of sheets for separators for light alloy wheels

Page 3-3 EWPS Wheel Pallet, Test instruction Dtermination of the material properties Appendix 6.1. and 6.2

Appendix 7 List of Approved Institutes and Consulting Engineers

Appendix 8 Drawings of Components: Base Pallet and Top Frame

Page 1-6 Pipe 13,14''

Page 2-6 Pipe 15, 16, 17, 18, 19, 20''

Page 3-6 Pipe 17.5, 19.5, 22.5"

-6 C Section 13'',14''

Page 5-6 C Section 15, 16, 17, 18, 19, 20''

Page 6-6 C Section 17.5, 19.5, 22.5''

Appendix 9 Drawings: Separators

Page 1-12 Separator for 13'' Wheels




Page 5-12 Separator for 17.5'' DC Wheels



12 Separator for 19.5'' DC Wheels

Page 7-12 Separator for 22.5'' DC Wheels

Page 8-12 Separator for 20'' TBS Wheels



Page 11-12 Separator for 19" Wheels

Page 12-12 Separator for 20" Wheels

Click on the format to have a list of the drawings of components:

IGS Format

Appendix 10 Initial Sample Report

Page 1-2 Form

Page 2-2 Scemes, Separator, Base Pallet, Top Frame

1 Introduction - CONTENTS

The VDA recommendation 4503 is the German version of the EUWA standard ES 4.01, valid for passenger car wheels 13'' to 20'', and of the EUWA standard 4.02, valid for 15°drop centre truck wheels 17.5", 19.5" and 22.5" and for 20" tapered bead seat wheels.

The purpose of this recommendation is to define the objectives and requirements the described load carriers must meet. The system component manufacturers have to make sure that development, construction and manufacturing comply with the valid safety standards and regulations.

EWPS components used before the publication of this recommendation (i.e. pilot series) are compatible components - even if they may differ in detail from this recommendation.

Note: All dimensions in mm, unless noted otherwise.

2 OBJECTIVES - CONTENTS

The EWPS standard has been designed to reduce the current packaging variety by standardising dimensions and construction thus optimising the costs of logistics for



manufacturers and customers.

This optimising has been achieved by:

standardised components, suitable for a 'pool system' throughout Europe

low system costs, low product cost

safe protection against product damage

high durability

being highly economical concerning volume and weight, freight and empties

low volume, low weight

standardised separators allowing general automatization of manufacturing and handling

cost-effective recycling (if necessary disposing)

being easy to repair

3 SYSTEM COMPONENTS - CONTENTS

EWPS Load units (LU) for transport and storage consist of:

- base pallet

- separators according to respective wheel size

- top frame

Top frame

- Dimensions match steel base pallet

- Functions as cover, stacking aid andstop against slipping of the wheels in the centre. Used if necessary.

Separators



Base pallet and top frame of designs A (Pipe Version) and B (C Section Version) can be used as compatible components.

4 HANDLING - CONTENTS

EWPS components are ergonomic and are easy to handle (low weight).

All components can be moved by (even simple) mechanical/automatic gripping systems.

The design of the base pallets, separators and top frames allows to establish self-locking load units whose heights depend upon the usable height of the respective transportation means (truck, wagon, container). According to the expected transport conditions, the load units are to be secured by devices like plastic strips and tightening straps.

The loaded units can be stacked up to 5 m.

5 IDENTIFICATION, COLOUR CODING - CONTENTS

- Dimensions match steel

- Functions as the load unand safety device

- PE deep-drawing foil 2.5 up to 3.0 mm thick for light alloy wheels: soft surface + 0.7 mm

- different designs accordidiameter

Steel base pallet

- Dimensions match steel

1200 x 1100 (size 1) for 13''and 14'' car wheels

1360 x 1145 (size 2) for 15'', 16'', 17'' 18'' 19" an

1210 x 1210 (size 3) for 17.5'', 19.5'', and 22,5''

truck wheels and 20" tapewheels



5.1 Type Designations - CONTENTS

The type numbers of the EWPS components are explained in Appendix 1. The numbers are

- written on a plate (base pallet and top frame)

- engraved into separator - as shown in the drawings

5.2 Identification Aid - CONTENTS

Coloured strips make identification easy. The strips are extruded on the separators (PE-HD). Minimum breadth of strips = 100 mm.

- Quality and design must comply with the specification, detailed in App. 6.

1) DC = Drop Centre Bead Seat Wheel

2) TBS = Tapered Bead Seat Wheel

6 GENERAL REQUIREMENTS - CONTENTS

The system and its components must

wheel diameter

steel wheels basic colour: charcoal grey similar to RAL 7016

light alloy wheels basic colour: upper surface charcoal grey, similar to RAL 7016; basic colour: lower surface black

strip colour: upper surface lateral strip colour: upper surface centric

13'' blue similar to RAL 5015 blue similar to RAL 5015

14'' green similar to RAL 6018 green similar to RAL 6018

15'' no strips grey similar to RAL 7032

16'' blue violet similar to RAL 4005 blue violet similar to RAL 4005

17" orange similar to RAL 2008 orange similar to RAL 2008

18" red similar to RAL 3002 red similar to RAL 3002

19" yellow similar to RAL 1018 2 strips centric

20" pink similar to RAL 3015 2 strips centric

17.5'' DC 1) yellow similar to RAL 1012 yellow similar to RAL 1012

19.5'' DC 1) blue similar to RAL 5015 blue similar to RAL 5015

22.5'' DC 1) no strips basic colour grey similar to RAL 7032

20" TBS 2) green similar to RAL 6018



- reduce the variety of pallets

- be suitable for a "pool system" (interchangeability)

- be usable for each step from wheel manufacturer to customer

- employ all current transport means/conveyor chains in a cost-effective way

- guarantee protection against damage during transport, storage and handling

- smoothly fit in the material flow process of storing, manufacturing and assembly

- be easy to handle

- designed according to ergonomic principles

- possibly be made of materials which are recyclings in the automobile industry

- be resistant to soiling and other external factors

- be easy to clean

- be recyclable

All system components must be exempt from patent and trade mark rights.

7 BASE PALLET AND TOP FRAME REQUIREMENTS - CONTENTS

7.1 Dimensions - CONTENTS

7.1.1 Overall dimensions

see table, according to Appendix 1

7.1.2 Fork opening base pallet

EWPS Pipe-Version

Type*

EWPS C-Section-Version

Type*

BP 1 BP 2 BP 3 BC 1 BC 2 BC 3

Entry free dimensions1) - max. height - max. width - Width of middle foot

95 790 220

95 1040 220

115 840 220

90 792 217

90 792 217

110 792 217

Underclearance2) - max. height - max. width

130 670

130 615

150 670

125 668

125 724

145 724



1) Free entry from four sides, lengthwise and crosswise, must be ensured - even stacked 2) The pallet must be passed under from two sides

7.1.3 Functional Characteristics

Functional characteristics and dimensions are shown in the drawings in Appendix 8. The purpose of theses drawings is to define the functional characteristics. They do not replace the constructional drawings needed for manufacturing.

7.2 Weight and Load - CONTENTS

7.2.1 Load

1,000 kg

Loading scheme to ISO TR 232, table 1, loading case 4

The 1,000 kg load must be transported and stored with all therein listed floor conveyors, continuous transporters, and storage equipment. No rip off and irreversible deformations must occur. Handled properly, no load must slip off the pallet due to deflection or deformation.

7.2.2 Maximum load

Maximum stacking height of loaded units: 5,000 mm Safety load 30 KN (bearing surface)

7.2.3 Tare

Base pallet truck and car about 25 kg Top frame truck about 15 kg Top frame car about 12 kg

7.3 Deflection - CONTENTS

According to ZH1/428: max. l/200, w/200.

7.4 Marking - CONTENTS

Base pallet and top frame are to be marked permanently according to ZH 1/428.

Allocation according to Appendix 1, design according to drawings.

7.5 Materials Handling Technology - CONTENTS

7.5.1 Roller conveyors

With standard rollers and bord rollers



Roller diameter 89 Roller distance 175 (210 max.)

Transportation lengthwise at all times, transportation crosswise not absolutely required on roller conveyors.

7.5.2 Chain conveyors

Transportation lengthwise and crosswise (lumped load)

7.6 Storage Technology - CONTENTS

Floor storage: stacking height 5,000 mm according to ZH 1/428

Shelf storage: storage in common shelves for wooden pallets (DIN 15146 T2 and T3) must be possible.

Deflection: max. l/200

No permanent deflection or deformation at a storing temperature of 60°C and a 30 day storage period.

7.7 System Features - CONTENTS

The pallet is constructed in a way that:

- upper side of the pallet form-fits into the lower side of the separator, thus providing positive safety

- pallets can be stacked safely and without friction

- top frames can also be stacked on top of pallets

- pallets and top frames can be stacked with and without separators

- empties can be stored without fastening device (if possible)

- empties can be transported with no safety device needed

- loaded units can be secured by plastic tightening straps, stretching or shrinking film when transported

- units can be transported by cranes with crane transport devices

- units can be handled by means of simple grab systems

Further requirements concerning construction/manufacturing:

- complete construction must be free of sharp edges (conveyor technique)

- smooth surfaces

- no recesses, as few openings as possible



- no entrainment of liquids when cleaned or stored outdoors

- long-time storage of pallets and top frames in the open must be possible (protection against corrosion)

- good air-drying (easy to clean)

- economical manufacturing repairing recycling/disposal

7.8 Environment - CONTENTS

EWPS components must be suitable for the European climate: it must be possible to transport, load and store them between -25°C and 75°C.

For this temperature range they must meet the requirements of this recommendation.

7.9 Material - CONTENTS

Breaking strength, abrasion resistance and deformation resistance, collision and impact resistance of the materials must be oriented to the requirements of this recommendation (see Appendix).

Lowest fire load.

Weatherproof and resistant to brittleness.

Cost-effectively recyclable and reusable, protecting the environment.

8 SEPARATORS REQUIREMENTS - CONTENTS

The separators are the EWPS system's pick up device for the wheels. They protect and secure the wheels in a load unit. The respective requirements are detailed below.

8.1 General Requirements - CONTENTS

protection and securing of the wheels during the transportation/loading process as well as protection and securing of the wheels in the bearing area ergonomic design for easy (manual) handling it must be possible to handle pallet, top frame, and separators with one and the same grab system economical manufacturing, possibly using materials which are recyclings in the automobile industry dirt-repelling, easy to clean cost effectively recyclable, reusable or disposable according to ecological principles

8.2 Design - CONTENTS



8.2.1 The separators should also serve as covering element (cover). The lower side of the base pallet must fit in the upper side of the separator of the unit below = stacking component.

8.2.2 Stacked loaded units must be secure without securing device

8.2.3 Stacked empties must be secure without securing devices

8.2.4 It should be achieved:

- form-fit positioning

- load must not slip on the separators

- safe transport with conveyor technology

- safe unpiling of the separators (holding surfaces)

8.2.5 Devices securing transport unit:

- recyclable plastic, strips, stretching or shrinking film

- if handled properly, securing devices prevent damage from separators when transported

8.3 Environment - CONTENTS

8.3.1 Temperatures of -25°C - 75°C without deformation

8.3.2 Colour fastness to light, UV ray resistant, weather-proof

8.3.3 Resistant to oil, gasoline, acids, alkaline solutions, coolants

8.3.4 Storage of separators in the open must be possible,

no closed niches

8.3.5 Further Characteristics

- easy to clean

- smooth surfaces

- no niches, few openings

- good air-drying must be possible

8.4 Material - CONTENTS

- lowest fire load

- manufacturing: using recyclings preferable from the automobile industry

- recyclable/reusable



- resistant to fracture

- resistant to wear

- deformation resistant

- collision and impact resistance must be oriented to requirements

- not harmful to environment

9 EXEMPT FROM PATENT AND TRADE MARK RIGHTS - CONTENTS

10 ECONOMICLY ACCEPTABLE SOLUTIONS IN TERMS OF CONSTRUCTION, MANUFACTURING, MATERIALS, AND ENVIRONMENT - CONTENTS

11 OPERATING CONDITIONS, TRAFFIC AND, EXCHANGE - CONTENTS

11.1 "User Pool" - CONTENTS

The EWPS System is designed to allow extensive logistic rationalisation - mainly due to joint use.

- The joint use of the EWPS System - according to this recommendation - provides the opportunity to install a "user pool".

- The "EWPS user pool" - according to this recommendation - is based on bilateral agreements and decentralised administration.

- The members agree on the amount of transport units required for the goods traffic

- The suppliers take care of acquisition.

- Using the EWPS components acquired for the goods traffic, the wheel suppliers become "pool members".

- According to the amount of acquired EWPS components the "pool members" have nominal possession of the "pool stock".

- The nominal possession of the "pool member" is bilaterally controlled.

- Losses of possession are to be replaced by the "pool members" themselves.

- Requirements are:

- complete and proper administration of the provided stock



- thorough and proper conduct of the "pool members"

- The arrangements concerning cost allocation are to be agreed upon bilaterally

11.2 Traffic and Exchange - CONTENTS

- EWPS-Identification

When traffic leaves the plant, the EWPS identification number and the customer's load carrier number have to be stated on the freight/delivery notes.

- Controlling and Monitoring

Permanently keeping accounts between the members - at least one monthly balancing. The EWPS consignee checks the numbers of EWPS components coming in/going out. Consignor and consignee accept the initial amount as the accounted amount - if there is no immediate report on differences (applies to loaded and unloaded consignments). Differences have to be sorted out immediately - followed by identical bookings. Undamaged components are to be circulated only. Wheel producers carry out or take care of repairs. As experience shows, the amount of components which have to be replaced due to wear or damage is to be assumed as 2% - 3% of all components in circulation.

11.3 Quality Assurance and Quality Control - CONTENTS

In their own interest, the manufacturers of EWPS components carry out checks/controls according to the valid quality requirements. They are to be recorded and can be inspected by the users.

Further quality controls can be agreed on bilaterally by manufacturer and customer.

To assure the quality standard of the EWPS system and to protect the users' interests, following arrangements are necessary:

Standardised quality requirements for system components, prototypes of each manufacturer and series production (see Appendix 2) The agreed checks and controls have to be carried out properly and completely EWPS system components must be authorised by the VDA/EUWA, thus supervising the EWPS system The users and prospective customers of the EWPS system can obtain information on manufacturers with registration number from the VDA/EUWA.

System users are committed to using system components with registration number only - thus guaranteeing the interchangeability of the pool system.



11.4 Transaction - CONTENTS

Quality regulations, drawings and material specifications are part of the VDA/EUWA recommendation. They can be found in the Appendix.

- The work shops "Wheel Pallet"/"Logistic commission" keep the appendix up to date.

- The necessary feed-back of the system's users (exchange of information) are to be directed to the VDA/EUWA.

11.5 Approval - CONTENTS

Manufacturers interested in producing and selling EWPS components present their prototypes to one of the institutes/consulting engineers authorised by the VDA/EUWA (see Appendix 7) for testing and certifying.

Certificate and prototypes are transferred either to VDA or EUWA working groups to issue a registration number, stating the certified manufacturer.

The relevant list of certified manufacturers can be obtained from VDA/EUWA.

11.6 Series Control/Quality Control - CONTENTS

The EWPS manufacturer has to keep up quality standards. Quality requirements are met if the tolerances specified in the appendix are observed.

The customers are free to agree on further controls or checks with the suppliers.

In case of reasonable doubt, customers can issue the testing of EWPS components. If defects are found, the manufacturer has to pay for the test and must cover all costs in connection with the replacements. Otherwise, the customer has to pay for the tests.

11.7 Performance Checks/Functional Testing - CONTENTS

Performance checks and functional testing concerning damage features - as listed in Appendix 4 and 5 - are carried out by the "pool members" thus maintaining functioning product flow between the "pool users".

11.8 Alterations - CONTENTS

Requests for alterations of EWPS system components must be presented to the VDA/EUWA work shops in written form. They will review proposals and grant permission for the introduction of alterations - also in written form. These alterations always come into force 2 months after the date of the written release.



12 Conditions of Quality Control - CONTENTS

The goods manufactured according to the VDA/EUWA recommendation must provide all functions according to this recommendation. They have to meet the following quality requirements. The VDA/EUWA has the right to check on quality standards and organise quality control.

12.1 Area of Application - CONTENTS

These quality requirements apply to all EWPS components:

- base pallets

- top frames

- separators

12.2 Quality Requirements - CONTENTS

12.2.1 Materials, Dimensions and Separator Colouring

Polyethylene with characteristics specified in Appendix 6 is the only approved material for the quality assured system according to the VDA/EUWA recommendation.

Dimension, materials and colouring of all components must comply with the specifications detailed in the corresponding drawings.

The drawings in the appendix of this recommendation provide general information only. Please write to the VDA or EUWA for the latest valid drawings:

Verband der Automobilindustrie e.V. (VDA) Hayes Lemmerz Holding GmbH

Westendstraße 61 D 53639 Königswinter

D-60325 Frankfurt/Main Ladestraße

Attn. Mr. H. Gumpert

Tel. 02223-71252

Fax. 02223-71312

12.2.2 Materials and Characteristics of Base Pallet and Top Frame

All system requirements are detailed in the corresponding drawings.

12.2.3 Assurance of Quality Requirements



Together with the specimen to be tested, the EWPS manufacturer provides the EWPS user with a certificate. Herein, an unbiased expert (see Appendix 7) certifies that the materials used for manufacturing meet the mechanical and thermal requirements detailed in Appendix 6. It also certifies that the materials, dimensions and designs of the components meet the requirements in the drawings in every detail and that manufacturing complies with the required regulations.

After positively testing the prototype and the series fabrication type, the EWPS user informs the VDA/EUWA on the test results. Then, a registration number will be issued, and the EWPS manufacturer will be included into the VDA/EUWA list of manufacturers.

13 USE AND MAINTENANCE - CONTENTS

In principle the wheel manufacturer is responsible for the cleaning of the relevant components of the EWPS System. Clean components are to be circulated only. After unloading the separators, it always has to be made sure that they are ready to use. They must be passed on to the next user undamaged and without any dirt which can be rubbed off.

Tags, labels etc. must not be stuck on to EWPS components; it is not allowed to write on them, since all this may cause misinformation, thus endangering the interchangeability of the system.

Due to the variety of the users' technical equipment, the users agree upon the cleaning of the separators and the question of costs bilaterally.

Repairs of the base pallets and separators are detailed in Appendix 4 and 5.

To ensure smooth progress of the EWPS product flow, damaged components are to be removed from the exchange system by the last user.

The system users are committed:

- to check on the quality and operatability of EWPS

- to pass on operative components only

- to repair, recycle, clean or dispose damaged EWPS components according to Appendix 4 and 5.

Appendix 1 EWPS Wheel Pallet Components - APPENDIX

Type designations and dimensions

System components

Wheel diameter in

inch

Design EWPS-Type

Drawing

Dimensions2)



No. length width height1)

13; 14 Pipe 1 BP 8461 1208 1118 195

C-Section 1 BC 8462 1203 1113 195

Base 15; 16; 17 Pipe 2 BP 8463 1358 1153 195 pallet 18; 19; 20 C-Section 2 BC 8464 1358 1148 195

16; 17.5; 19.5 Pipe 3 BP 8465 1208 1208 215

20; 22.5 C-Section 3 BC 8466 1208 1202 215

13 13 S 8467 1195 1105 59.5

14 14 S 8468 1195 1105 59.5

Separators 15 15 S 8469 1360 1145 59.5

16 16 S 8488 1360 1145 60.2

PE-HG 17 17 S 8474 1360 1145 59.5

18 PE-HD 18 S 8475 1360 1145 59.5

for 19

steel 20

wheels 7) 17.5 DC 17.5 S 8471 1210 1210 72.5

7) 19.5 DC 19.5 S 8472 1210 1210 72.5

4) 7) 22.5 DC 22.5 S 8499 1210 1210 72.5

6) 20 TBS 20 S 8477 1210 1210 40

13 13 L 8478 1195 1105 60.2

Separators 14 14 L 8479 1195 1105 60.2

PE-Stop 15 15 L 8480 1360 1145 60.2

for- 16 PE-Stop 16 L 8487 1360 1145 60.2 light alloy 17 17 L 8482 1360 1145 60.2

wheels 18 18 L 8484 1360 1145 60.2

19 19 L 8497 1360 1145 60.2

20 20 L 8498 1360 1145 60.2

5) 13; 14 Pipe 1 TP 8507 1208 1118 100

C-Section 1 TC 8508 1203 1113 100

Top 5) 15; 16; 17 Pipe 2 TP 8509 1358 1153 100

frames 18; 19; 20 C-Section 2 TC 8510 1358 1148 100

17.5; 19.5; Pipe 3 TP 8495 1208 1208 110

20; 22.5 C-Section 3 TC 8496 1208 1208 110



1) Height including stacking edges, height of stacking edges 30 mm. Distance between empty separators stacked: PE-HD = 10 +1 mm; PE-Stop = 10.7 +1 mm

2) For dimensions, please check drawings

3) The descernible deriation within the dimension for the lengths and widths of pipe, c-section base pallets and top frames are caused by the design and do not interfere the compatibility of the EWPS components

4) Replacement for 8473

5) Replacement for 8491, 8492, 8493 and 8494

6) TBS tapered bead seat wheel

7) DC Drop centre bead seat wheel

For enquiry and up to date information, please order valid drawings from the VDA or EUWA. For addresses see 12.2.1

Appendix 1 EWPS Wheel Pallet Components - APPENDIX

Type Designations, Abbreviations

1 Component identification: Steel Base Pallet and Top Frame

Example: E W P S - 1 - B P

Digit: 1 2 3 4 - 5 - 6 7

Digits 1 to 4: EWPS, system name European Wheel Pallet System

Digit 5:Basic number for nominal size 1 = 1200 x 1100 2 = 1360 x 1145 3 = 1210 x 1210

Digit 6 Component identification B = Base Pallet T = Top Frame

Digit: 7Component identification P = Pipe-Version C = C-Section-Version

2 Component identification separators



Example: E W P S - 1 3 - L

Digit: 1 2 3 4 - 5 6 - 7

Digits 1 to 4: See above

Digits 5 and 6:Nominal diameter of wheel in inch

Digit 7:Application data, suitable for: S = Steel Wheel L = Light Alloy Wheel

Appendix 2 EWPS Wheel Pallet - APPENDIX

Checks required for base pallet and top frame licensing

General Requirements

a. Generally, only finished products manufactured with tools and equipment in series can be certified and tested (no prototypes, no hand specimen).

b. Certifying and testing must be completed before series production starts.

c. Amount of inspection and test results must be documented in an expertise.

Minimum Testing Requirements

a. Raw material test on steel quality, dimensions and technical terms of delivery to DIN 2395 Part 1 + 2 (or subsequent standards).

b. Visual examination of the general quality of design (straightness, welding seams etc.).

c. Review of the constructional drawings: they must meet the requirements of this recommendation concerning functions and functional dimensions.

d. Inspection of welding seams according to the "Kleinen Eignungsnachweis" to DIN/EN 719.

e. Inspection of painting, preparatory treatment and thickness of painting.

f. Statical calculation must be submitted.




Checks required for plastic separator licensing

General Requirements

a. Generally, only finished products manufactured with tools and equipment in series can be certified and tested (no prototypes, no hand specimen).

b. Certifying and testing must be completed before series production starts.

c. Amount of inspection and test results must be documented in an expertise.

Minimum Testing Requirements

a. Tests of the plate's material using the manufacturer's certificate; according to the specifications detailed in Appendix 6.

b. Review of the constructional drawings: they must meet the requirements of this recommendation concerning functions and functional dimensions.

c. Visual examination of the general quality of design.

Appendix 4 EWPS-Wheel Pallet - APPENDIX

Damage list base pallet and top frame

Number

DAMAGE FEATURE

Recycling*

limited usage or repair as agreed upon

1 visible fractures x

2 missing functional edges and corners like:

2.1 damaged stacking edges x

2.2 damaged pallet foot x

2.3 damaged functional frame stretches, top side

x

2.4 damaged functional frame stretches, lower side

x

2.5 damaged outer profiles x

3 permanent soiling x



* Recycle-as-you-damage principle


Damage feature separators

* The manufacturer is committed to take back the PE separators, to have them granulated and to recycle the granule.

Appendix 6.1 EWPS Wheel Pallet - APPENDIX

Technical data of sheets for separators for steel wheels

4 permanent deformation x 5 soiling x

6 excessive corrosion x 7 missing identification tag x

Number

DAMAGE FEATURE

Recycling*

limited usage or repair as agreed upon

1. visible fractures x 2. missing functional edges and corners

like:

2.1 damaged protective pots x 2.2 damaged recessed grips x 2.3 damaged positive positioning cams x 2.4 damaged negative positioning cams x 2.5 damaged outer profiles x 2.6 PE-Stop: damaged surface x

2.7 brittleness x 3 permanent deformation x 4 permanent soiling x

disposal/ down cycling

5 soiling x cleaning



cleaning: High pressure cleaner (e.g.: Kärcher HDS 995, Powerdüse 25°); max. pressure 170 bar at watertemperatur of max. 140° C, 45° spry-angle and min. 15 cm distance from interleave surface; surface-active agent based detergents can be used.

resistant: diluted acids, liquors, petrol and water.

not resistant to: Oxidizing acids, ketones, aromatical and chlorinated hydrocarbons and detergents.

Appendix 6.2 EWPS Wheel Pallet - APPENDIX

Technical data of sheets for separators for light alloy wheels

Properties Standard Testing conditions

Unit Value

Density

DIN 53 479

g/cm³

0,95

Mechanical Properties

Modulus of elasticity DIN 53457 N/mm2 1000

Tensile stress at yield DIN 53 455 N/mm2 20

Elongation at break DIN 53 455 % >50

Impact strength at R.T. EN ISO 179/eU KJ/m2 n.B.

Hardness (Shore D)

DIN 53 505 Shore D 65

Coefficient of friction internal 2 - 0,19 Coefficient of abrasion PA 03020 3 - 1

Thermal Properties

Melting point PA 03012 1 °C 131/163 MFI (190/10) DIN 53735 g/10min 2,0

Recommended temp. for use

DIN 53735 °C -25/+75

Properties Standard Testing conditions

Unit Value

Density

DIN 53 479

g/cm³

0,94

Mechanical Properties

Modulus of elasticity DIN 53457 N/mm2 900

Tensile stress at yield DIN 53 455 N/mm2 10



cleaning: High pressure cleaner (e.g.: Kärcher HDS 995, Powerdüse 25°); max. pressure 170 bar at watertemperatur of max. 140° C, 45° spry-angle and min. 15 cm distance from interleave surface; surface-active agent based detergents can be used.

resistant to: diluted acids, liquors, petrol and water. The soft-layer can by lightly swollen by grease and oil.

not resistant to: Oxidizing acids, ketones, aromatical and chlorinated hydrocarbons and detergents.

Appendix 6.3 EWPS Wheel Pallet APPENDIX Test instruction - Determination of the material properties Appendix 6.1, 6.2

Elongation at break DIN 53 455 % >50

Flexural modulus DIN 53 452 N/mm2 400

Bending strength DIN 53 452 N/mm2 12

Elongation at Fmax DIN 53 452 % 8

Impact strength at R.T. EN ISO 179/eU KJ/m2 n.B.

Hardness (Shore D)

DIN 53 505 Shore D Soft-layer: 52 Substrate: 65

Coefficient of friction internal 2 - Soft-layer: 0,75 Substrate: 0,19

Coefficient of abrasion PA 03020 3 - 0,15 Thermal

Properties

Melting point PA 03012 1 °C Soft-layer: 117/163 Substrate: 131/163

MFI (190/10) DIN 53735 g/10min 4,0

Recommended temp. for use

- °C -25/+75

Property Standard Testing conditions

Description

DSC melting point

PA

03012

1

Determination of the melting point by DSC-Analysis

Evaluated is the second run




List of approved institutes and consulting engineers

1. List of approved institutes ans consulting engineers for EWPS-components:

- SGS-Control-GmbH Dipl.-Ing. H. Dahle Raboisen 28

D-20095 Hamburg

Tel.: 040 / 3 01 01-0

- Incos GmbH Ingenieurbüro Dipl.-Ing. Schreiner Am Galgenberg 9

D-85135 Titting

Tel. 08423 / 99 19-14 Fax 08423 / 99 19-55

2. List of approved institutes and consulting engeneers for plastic sheet materials for separators:

- DEUTZ MOTOR GmbH Ein Unternehmen der KHD-Gruppe H. Malzbender Deutz-Mülheimer Str. 147

51063 Köln-Deutz

Coefficient of friction internal 2 Aluminium versus soft - layer cc. substrate surface roughness of Alu: Ra=0,61 µm; Rt=8,32 µm

Coefficient of abrasion PA 03020

3 The coefficient of abrasion is determined on the basis of weight loss of a sample to a reference sample (HDPE-substrate). This sample is blasted with quartzsand by a high pressure machine on the coated side under definated conditions.



Tel.: 0221 / 8 22-24 47 Fax.: 0221 / 8 22-30 22

- Süddeutsches Kunststoff-Zentrum Prüfung und Forschung Gpl. Folien und Bahnen Herrn Glück Frankfurter Str. 15-17

97082 Würzburg

Tel.: 09 31 / 41 04-1 50 Fax.: 09 31 / 41 04-1 77

(Please contact VDA for the latest list of approved consulting engineers )

Appendix 10 EWPS Wheel Pallet, sheet 1-2 - APPENDIX

Initial sample report for EWPS components Test in accordance to VDA 4503 and EUWA ES 4.05

component: drawing-No.:

base pallet EWPS separator EWPS top frame EWPS manufacturer, adress:

location of manufacturing, subsidiary, associated company:

test was performed in date: by institute address VDA-approval No.:

1. material test according to appendix 6.1/6.2

result: passed not passed



2. dimension test/operational dimensions

name of dimention base pallet separator top frame

ok. not ok. ok. not ok. i.O. n. i.O.

1

2

3

4

operational dimensions


3. operational test with master-sample performed at: date

by manufacturer: town:

stackability ok. not ok.

shape of fixing noses ok. not ok.

shape of protecting cap ok. not ok.

marking ok. not ok.


4. check of remaining dimensions

passed not passed

5. approval effected yes no

Issued location: date: name of inspector:



Appendix 10 EWPS Wheel Pallet, sheet 2-2 - APPENDIX

Separator

Base pallet

operational dimensions on the drawing especially marked

1 outer dimensions lengthd / widths 2 wheel positioning diameter 3 positioning of separator of the base pallet 4 thickness

remark: Dimension test earliest 24h after manufacturing. Sample temparatur about 20 °C.

1 outer dimensions compare drawing 2 diagonals compare drawing 3 fixation to dimension separator compare drawing 4 thickness

Top-Frame

1 outer dimensions compare drawing 2 diagonals compare drawing 3 positions of struts compare drawing mark 4 thickness



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