OFFICIAL COLLEGEAND“JULIO SOLER” ASSOCIATIONOFINDUSTRIAL ENGINEERS OF CANTABRIA (SPAIN)

ANALISYS OF THE STRENGTH TO ROLLOVER OFBUSES SUPERSTRUCTURE

PROPOSAL TO MODIFY THE CURRENT EUROPEAN DIRECTIVES FOR THE INCREASE OF

THE SAFETY OF USERS

May 2003

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INDEX 1.- ENTITIES INTRODUCTION. 2.--REASON OF THIS PROPOSAL. 3.- BUS SKETCH. 4.- EFFECTS OF ROLLOVER ACCIDENTS ON BUSES. 5.- BUS ACCIDENTS: 5.1.- ON THE 14-11-2001 IN HUELVA (SPAIN) : 20 DEAD. 5.2.- GENERAL VIEW OF BUS AFTER ROLLOVER ACCIDENT. 6.- EUROPEAN ROLL-OVER REGULATIONS ON BUSES. 6.1.-APPROVAL OF THE STRENGTH OF BUSES SUPERSTRUCTURE ACCORDING TO THE R. 66 AND

THE D. 2001/85/CE. 6.2.- R. 66 AND D. 2001/85/CE: ROLL-OVER TEST. 7.- ROLL-OVER DIRECTIVE FOR THE AGRICULTURE OR FORESTRY TRACTORS. 7.1.- D. 7/536/CEE: IMPACT AT THE SIDE TEST. 7.2.- D. 7/536/CEE: IMPACT AT THE FRONT TEST. 7.3.- D. 7/536/CEE: ROOF CRUSHING TEST. 8.-COMPARATION BETWEEN BOTH DIRECTIVES. 9.- U.S.A. REGULATIONS. 10.-PROPOSAL TO MODIFY THE BUSES DIRECTIVES. 11.-HYDRAULIC TESTS ACCORDING TO ISO 3771:

11.1.- LATERAL: FORCE AND DEFLECTION TESTS.11.2.- VERTICAL FORCE TEST.11.3.- LONGITUDINAL: FORCE TEST.

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1.-ENTITIES INTRODUCTION

THE OFFICIAL COLLEGE ANDTHE “JULIO SOLER” ASSOCIATION,OF INDUSTRIAL ENGINEERS OF CANTABRIA

• The Official College of Industrial Engineers of Cantabria is a publiccorporation created by the decree of the Industry and TradeMinistery on the 9th of april 1949.

• The “Julio Soler” Association of Industrial Engineers of Cantabria,is a private one founded in 1918 and is member of the SpanishInstitute of the Engineering (I.I.E.) through the Federation ofSpanish Associations of Industrial Engineers. The I.I.E. belongs toeuropean and world organisations as the European Federation ofNational Engineering Associations (FEANI) and to the WorldFederation of Engineers Organisations (WFEO).

• Both are non-profit making entities and work together tightely inthe industial engineering field.The number of members in eachone is of 510.

.

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2.-REASON OF THIS PROPOSAL

The alarming high number of dead in accidents with victims ( 25dead / accident.Only in last 10 years in Spain, The 8 more serious bus accidentshave produced the following killed victims: • 9 - 5 -92. ------------------------------------17• 19- 8 -92. ------------------------------------46• 15- 6 -95. ------------------------------------14• 10- 7 -95. (Spanish bus in France)--------------23• 28- 2 -96. ------------------------------------29• 19- 9 -99. ------------------------------------28• 6- 7 -00. ------------------------------------28• 14-11-01. ------------------------------------20 Total 205 killed

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3.- BUS SKETCH

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4.- EFFECTS OF ROLL-OVER ACCIDENTS ON BUSES

EFFECTS DUE TO SUPERSTRUCTURE FAILURE:Superstructure deformation:

• Disappearance of the protection volume for the passengers.

EFFECTS DUE TO WINDOWS FAILURES.• Breakeage of the side windows:• Throwing of passenger off board, increased by no fixing

system of passengers to seats.

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5.1- ACCIDENT ON THE 14-11-2001 IN HUELVA (SPAIN):20 DEAD

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5.2- GENERAL VIEW OF BUS AFTER ROLLOVER ACCIDENT

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6.- EUROPEAN ROLL-OVER REGULATIONS ON BUSES

•Regulation No. 36 of the UN Economic Commission for Europe(UN/ECE) on Uniform Provisions concerning the Approval of LargePassengers Vehicles with regard to their General Construction,which is anexed to the Agreement of 20 March 1958, concerningthe adoption of uniform conditions for approval and reciprocalrecognition of approval for motor vehicle equipment and parts.

•Directive 2001/85/EC of the European Parliament and of theCouncil of 20 November 2001 relating to special provisions forvehicles used for the carriage of passengers comprising morethan eight seats in addition to the driver´s seat, and amendingDirectives 70/156/EEC and 97/27/EC.

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6.1.- APPROVAL OF STRENGTH OF BUSES SUPERSTRUCTUREACCORDING TO THE R. 66 AND THE D. 2001/85/CE

• Each type of vehicle shall be verified according to one of thefollowing methods at the discretion of the manufacturer:

• Roll-over test on a complet vehicle.• Roll-over test on a body section or sections representative of

a complet vehicle.• A pendulum test on a body section or sections.• A verification of strength of the superstructure by calculation.

• The approval according to the R. 66, complies with therequirements of this Directive.

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• E = 0,75 x M x g x h, where:• E = energy in J ; 0,75= reducer coef.• M = unloaden mass of bus in kg• g = gravity acceleration in m/s2

• h = fall of bus gravity center from its maximum height in m.

6.2.- R. 66 Y D. 2001/85/CE – ROLL-OVER TEST

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7.- ROLL-OVER DIRECTIVE FOR THE AGRICULTURE ORFORESTRY TRACTORS

Council Directive of 28 June 1977 on the approximation of the lawsof Member States rating to the roll-over protection structures ofwheeled agiculture or forestry tractors (77/536/CEE).

Binding tests for its approvaL:

• Side impact test

• Front and rear impact tests.

• Front and rear crushing roof tests.

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E = H x M x g = x M x g ; where:

E= pendulum weigth energy in J

H= the height of fall in m

M= Mass of pendulum weight in kg

g= gravity acceleration in m/sq m

×+

100015,0125 tractorM

7.1.- D. 77/536/CEE: SIDE IMPACT TEST

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7.2.- D. 77/536/CEE: FRONT IMPACT TEST.

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7.3.- D. 77/536/CEE: ROOF CRUSHING TEST

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8.- COMPARATION BETWEEN BUSES AND TRACTORSDIRECTIVES.

• Energy per mass unit transmmited to the structure ofboth vehicles, a 13000 kg mass bus and a 2000 kgmass tractor, by their own tests:

For the bus: 6,18 J/kgFor the tractor: 9,37 J/kg

• Energy per mass unit transmited to the superstructure ofthe bus in its test , and to the structure of the tractor in itsside test:

For the bus: 6,18 J/kg. For the tractor: 4,17 J/kg

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• The Code 49 CFR Ch. V (10-1-01 Edition), and its Standard No.208; “Ocupant crash protection” says: Buses, first option, thefollowing:

• 1.-S4.4.2.1.The vehicle shall meet the crash protectionrequirements with respect to an anthropomorphic test dummyin the driver´s designated seating position.....

• 2.- S5.1.2(1). Impact a vehicle travelling longitudinally forwardat any speed up to 48 km/h into a fixed rigid barrier....

• 3.- S5.2. Impact a vehicle laterally on either side by a barriermoving at 20 mph....

• 4.- S5.3. Subject the vehicle to a roll-over test in either lateraldirection at Federal Regulations corresponding to the NationalHighway Traffic Safety Administration, 30 mph....with a testdummy placed in the front outboard....

9.- U.S.A. REGULATIONS

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10.- PROPOSAL TO MODIFY THE BUSES DIRECTIVES

• A 1.-Superstructure tests:1.-Side: Same as Directive 2001/85/CE.2.-Front and rear: Similar to tractors D. 77/536/CEE.3.-Roof crushing : Similar to tractors D. 77/536/CEE.

• A 2.-Superstructure tests :Hydrulic tests on roll over suporting structure (arch pillars)similar to ISO 3471, Earth moving machinery.1.-Lateral: Force and deflection tests.2.-Vertical and longitudinal: Force tests.

• B.- Body work modification:1.-Decreasing the size of inside window´s glass.2.-Reinforcing passangers side and roof of bodywork.

• C.- Seat belts system:1.-Binding its installation and use, avoiding intrusion inpassanger space.

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11.1.- LATERAL FORCE AND DEFLECTION TESTS, ISO 3471.

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11.2.- VERTICAL FORCE TEST , ISO 3471.

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11.3.- LONGITUDINAL FORCE TEST, ISO 3471.