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Insert the title of your presentation herePresented by Name HereJob Title - Date
Development of technical requirements / performance specifications for functional and occupational safety topics of agricultural and forestry vehicles.
Brian Robinson CEng CEnv MIMechE
Principle Consultant (Safety & Sustainability)
Project overview
Analyse various safety subjects, as specified by EC
Define performance specifications, where possible as precise values or ranges of acceptable values, through reference to well established and relevant standards
Determine the test requirements
Aim: To provide “a complete document of safety specifications and related tests that will allow for the approval of agricultural and forestry vehicles with respect to the safety subjects concerned”
Scope: Main focus on categories T and C. Other agricultural/forestry vehicle types (R & S) to be considered where relevant. Other types not being addressed (e.g. L, N, O), but opportunities for harmonisation with categories T/C/R/S to be considered. No detailed new test procedure development/validation
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ROPS for high clearance tractors and light tractors other than narrow track tractors
Foldable ROPS
FOPS Heating systems
Protection against penetrating objects (OPS) Spray suppression for vehicles >40 km/h
Controls, esp. safety & reliability of control systems, emergency and automatic stop devices
Visibility , information and info devices
Uncontrolled movements Warning of residual risks
Slips, trips & falls risks, esp. for wide tractors Lightning protection
Isolation of energy sources Fire risks
Guards & protective devices Vehicle control aids
Vehicle structure integrity Exposure to extreme temperatures
Stability of narrow track tractors Electrical safety, including static electricity
Devices to prevent unauthorised use Variations in operating conditions
Materials & products Tyres
Ergonomics, with emphasis on:•Protection against foreseeable misuse•Usability of control systems•Accessibility of controls to avoid unintentional activation•Adaptation of HMI to foreseeable driver characteristics•Vibrations•Operator intervention
The safety topics…
Project methodology
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Task 1 Task 2 Task 3 Task 4
Start: October 2012
Stakeholder consultation phase: Nov 2012 – Feb 2013•To include email questionnaire, accident data study, dedicated stakeholder workshop(s)•+ updates/inputs from WGAT meetings and informal working group•Literature review also designed to address questionnaire issues, and to make use of references suggested by stakeholders
End: May 2013
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Key questions…
What standards/requirements already exist? (Q6)
Are they suitable for agricultural/forestry vehicles? (Q7)
How important is the topic from a safety priorities perspective? (Q8)
Do requirements need to vary between vehicle categories? (Q9-10)
Can requirements be harmonised with other vehicle types? (Q11)
Is there a good evidence base? (Q12)
Q6 & Q7…ROPS & FOPSOECD Codes 3, 4, 6, 7 and 8 cover protective structures for agricultural and forestry vehicles- Specifies dynamic and quasi-static tests to test strength of ROPS
OECD Code 10 (& 2010/52/EU) covers Falling Object Protective Structures (FOPS) for Agricultural and Forestry Vehicles- 45kg sphere dropped on FOPS in various locations- Structure or sphere must not enter ‘safety zone’ inside occupant compartment
Australian National Code of Practice for Light Vehicle Construction and Modification, Section LK Seating and Occupant Protection for Roll-bars and Roll-cages - version 2.0 2011- Stipulates an exclusion zone relative to the occupant’s head where roll-over structures must not be fitted
Directive 2009/57/EC - Roll-over protection structures of wheeled agricultural or forestry tractors- Tractor ROPS impacted with 2 tonne pendulum on front, rear and side of ROPS- Tractor ROPS crushed vertically at the front and rear
ISO 3471:2008 Earth-moving machinery - Roll-over protective structures – Laboratory tests and performance requirements- Defines a testing standard for ROPS for earth-moving machinery (loader, dozer, tipper etc. over 700kg)
ANSI/ROHVA 1-2011- Recreational Off-Highway Vehicle Association standard includes ROPS standard
87/402/EEC & 86/298/EEC (both amended by 2010/22/EU)
2006/42/EC (Machinery Directive)
ISO 3463, 3776, 5700, 12003, 27850, 3449
NFU 02-052, NF EN 1459
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Devices to prevent unauthorised use- UN Regulation No. 116 applies to vehicle categories M1 and N1. It defines type approval requirements
for devices to prevent unauthorised use. May form a basis for requirements for categories T and C. Provisions for non-motorised R and S category vehicles might need to differ.
- SAE J1083 applies to machinery. It is a guide for locking or otherwise rendering inoperative the starting, control, and parking release systems to deter unauthorized machine or working tool movement while the machine is shut down.
- ISO 26322-1 and -2, 15077
Guards and protective devices: Protection from surfaces at high temperatures, protection against mechanical hazards, including protection against rough surfaces, sharp edges and angles, rupture of pipes carrying fluids and uncontrolled movement of the vehicle- Directive 76/432/EEC covers some uncontrolled movements (parking brake). Engine powered
movement of the vehicle after the driver left the cabin is not adequately covered; CEMA proposal regarding a "dead-man switch“ under development.
- Directive 2009/144/EC applies to the vehicle categories T1, T2, T3, T4. It provides general guidance for guards and protective devices and on the risk due to sharp edges and angles. Contains extensive definitions of dangerous parts and safety distances.
- Directive 2009/58/EC applies to tractors with 6 km/h≤vmax≤40 km/h. It defines the requirements for a tractor’s coupling device for towing.
- ISO/TS 28923 and 28924 apply to agricultural machinery. They specify the safety requirements and their verification for the design and construction of guards for the moving parts of the power transmission.
- EN 474-1, article 5.3.2.2 Pipes and hoses: forbids high pressure hoses in the cabin and requires diverting covers. Standards for connectors and hoses depend on the fluid, pressures, and flow.
- ISO 26322-1 and -2 apply to standard and small tractors respectively. They specify general safety requirements and their verification for the design and construction of these vehicles.
- ISO 13854, 13857, 4413:1998, 500-1, 8759-1, 13732-1- EN 14930
Q6 & Q7…
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Operating space and access to the driving position, including protection against slipping, tripping or falling- Available standards: Directive 80/720/EEC- ISO 4252 for agricultural tractors defines the minimum dimensions of their access doorways, details of
emergency exits, and their minimum internal clearance dimensions.- ISO 4253 for agricultural tractors defines dimensions for the operator's seat and the location of specific
controls (steering-wheel, clutch, brake and throttle pedal).- Vehicle categories T4.3, T2, T5, C, R, S are not fully covered by the above mentioned standards.- ISO 26322-1 & -2
Controls, including safety and reliability of control systems, emergency and automatic stop devices- Available standards: Directive 86/415/EEC, UN Regulation No. 13H- ISO 26262 applies to M category vehicles. It adresses the functional safety of safety-related E/E
systems and addresses possible hazards caused by malfunctioning behaviour of these systems, including their interaction.
- Directive 2010/22/EU amends Directive 86/415/EEC and applies to wheeled agricultural or forestry tractors. It has added requirements for Power take off controls - operation/shut off.
- UN ECE R13- CEMA OPC for PTO proposals under development- ISO 15077, 26322-1, 25119
Tyres- ETRTO standards- ECE R54
Protection against penetrating objects (OPS):- None identified thus far (apart from 2010/52/EC & ISO 8084 already identified)
Q6 & Q7…
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Isolation of energy sources:Electricity, Rotating parts (power take off), pressure vessels- Directive 2009/61/EC and 75/323/EEC refer to ISO 1724, a standard 7-pin trailer light connector,
it is low voltage (12V) and fused- PTO covered by Directive 86/297/EEC, referencing ISO 500-1 to 3.
PTO guards by BS EN 12965:2003.- ECE 100- 2009/144/EC
Electrical safety, including lightning protection & static electricity:- Draft BS IEC/TR 62713 provides some general information of what structures provide protection and
what people should do. - UNECE R34 on fuel tank design has a short article requiring earthing of fuel tanks to the chassis to
prevent sparks- ISO 4254-1, 26322-1, 15003, 10605, 14982- IEC 60801-2- EN 60204- 75/322/EEC, 89/173/EEC
Driver visibility & info systems- ISO 10975, (DIS) 5721- ECE 46, 43
Vehicle structure integrity:- 79/622/EEC, 86/298/EEC, 87/402/EEC
Q6 & Q7…
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Fire risks:- UNECE Regulation 34 covers the design of fuel tanks, and the mitigation of risk in design for general
use, collisions, and exposure to fire.- UNECE Regulation 118 and Directive 95/28/EC cover the fire resistance of materials used in vehicle
interiors ISO 3795:1989 is a fire burning rate test which is limited to 200mm/min in EN 474-1:2009- EN 474-1:2009 also states vehicles >1,500kg require a space for fire extinguisher - ISO 4254-1, 26322-1
Heating systems:- Newly identified: EN 474-1:2006+A1, ISO/DIS 10263-4:2007, ISO 10263-4:2009, ISO 14269-
2:1997: - All of the above standards seem to stem from the same route, they state requirements and testing but
not specific designs:- Must be able to raise the cabin temperature by ≥25°C from -15°C - Able to maintain at least 18°C (a standard minimum for workers)- This is tested at three places equivalent to the drivers: feet, head and hips.
- ECE 122- 2001/56/EC
Driver control aids:- StZVO 41- ECE 13
Spray suppression systems:- (EU) 109/2011- 91/226/EEC
Q6 & Q7…
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Information, warnings & markings:- Control symbols: Two standards found, both linked: BS ISO 3767-4:1993 (updated 2008) & BS ISO
3767-1:1998 (updated 2012). Both give a very through database of symbols to use. Some do not seem to be very intuitive and questions re the level of testing that went into their development?
- Hazard labels: BS ISO 11684:1995. Seems to be a thorough document specifying label layout and a large symbol directory. Perhaps some scope for more guidance on the placement of the labels on/within the vehicles?
- 86/415/EEC contains a database of symbols, but more limited than BS ISO 3767.- ECE 121. As for 86/415/EEC, it contains a database of symbols. More thorough than 86/415/EEC but
still less so than BS ISO 3767.
Ergonomics, especially vibrations, usability of controls and variations in operating conditions:- Seating/vibration:78/764/EEC is vague on comfort requirements. Seemingly is does not cover
materials and does not require tests of driver comfort. Perhaps this is an area for future development?- 2002/44/EC is a general directive on vibration over an 8-hour reference period. Applies to all people at
work. 78/764/EEC (last updated 2007) is specifically aimed at wheeled agricultural or forestry tractors. It is much more prescriptive in terms of how vibration at any given time is to be measured, although defers to 2002/44 in terms of overall exposure limits. 78/764 also goes further and covers seat design, specifying dimensions.
- Cab Ergonomics: BS ISO 15077:2008 found that relates specifically to controls of tractors and agricultural vehicles, covers actuating forces, displacement, location and method of operation.
- Several standards covering control positioning (BS ISO 4040:2009, ECE 35) and operating space (ISO TR 9511, 80/720/EEC). ECE 35 is aimed at cars and so whilst covering the principles may not be directly transferable; and ISO 4040 is generic motor vehicles so clear for generic controls but not for novel agricultural controls.
- Operating conditions: Found BS ISO 16154:2005, which covers lighting and marking requirements for travelling on public roadways.
Q6 & Q7…
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ROPS for high clearance tractors and light tractors other than narrow track tractors
Foldable ROPS
FOPS Heating systems
Protection against penetrating objects (OPS) Spray suppression for vehicles >40 km/h !!!
Controls, esp. safety & reliability of control systems, emergency and automatic stop devices
Visibility , information and info devices
Uncontrolled movements Warning of residual risks
Slips, trips & falls risks, esp. for wide tractors Lightning protection
Isolation of energy sources Fire risks
Guards & protective devices Vehicle control aids
Vehicle structure integrity Exposure to extreme temperatures
Stability of narrow track tractors Electrical safety, including static electricity
Devices to prevent unauthorised use Variations in operating conditions
Materials & products Tyres
Ergonomics, with emphasis on:•Protection against foreseeable misuse•Usability of control systems•Accessibility of controls to avoid unintentional activation
Key:
• Adaptation of HMI to foreseeable driver characteristics• Vibrations• Operator intervention
Highest risk – multiple, frequent fatalities Medium risk – some fatalities
Lower risk – occasional fatalities Lowest risk – no fatalities
Q8 Prioritising topics…UK fatal (off-road) accidents
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Q8 Key safety issues… from UK fatality recordsLoss of control, stability and ROPS, especially for quad bikes
Driver visibility when reversing
Uncontrolled movement
Emergency/automatic stop devices
Electrocution via vehicle/trailer contact with Overhead Power Lines
Falling objects, especially hay bales
Unsafe maintenance, especially disconnection of hydraulic hoses
PTO entanglement
Slips, trips & falls from vehicle or trailer
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Next phase…Task 3For each safety topic:
A summary of its relevance and risk profile during operation and/or mobility, and how that relevance is affected according to vehicle type and maximum speed;
A summary of the existing requirements, specification and/or test procedures identified and identification of those best suited to each vehicle type;
A discussion of opportunities for the safety specifications to be harmonised with other vehicle types;
Draft technical requirements and, where required by the evidence resulting from Tasks 1 and 2 and by the co-decision text, more detailed performance specifications and approval test procedures.
- This will use a decision hierarchy approach, prioritising each topic according to injury risk, its suitability for approval testing and the availability of appropriate test procedures.
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ROPS for High-Clearance Tractors (T4.1)
Stability and ROPS performance / test requirements developed forFrench national approval purposes
Are these requirements also suitable for application to similar vehicles across the EU?
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ROPS for Light Tractors (T3) …. ≤600kg
UK-based ROPS research has shown that current EC / OECD / ISO ROPS (strain energy-based) test criteria can be applied with confidence to tractors of unladen mass ≥300kg
Is there a need to consider ROPS for vehicles of <300kg?
Can ROPS be effectively installed on <300kg vehicles?
Can a normal tractor be <600kg and not be ‘narrow’?
Both these examples are >600kg
OECD Narrow-Track (T2) Tractor test codes already encompass m≥400kg
Are many ‘conventional’tractors <400kg unladen?
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Folding ROPS
Can be fitted to any category of tractor
Intended only to permit operation in areas of restricted headroom
Also fitted to ‘medium’-sized tractors
Test procedures / requirements are well-established
Is there a problem ‘in use’?
A folded ROPS cannot protect the operator
Are there practical / ergonomic issues with the physical effort required to fold / re-erect the ROPS?
Or is it a simple operator failure to bother to re-erect the ROPS due to the needs of local operating conditions?
Can legislative requirements hope to change this scenario?
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Stability
Directive 87/402/EEC (OECD Code 6) – front-mounted ROPS for T2 tractors already includes a 38 degree minimum stability requirement and a non-continuous rolling requirement …. As does French national requirements for T4.1 tractors
Directive 86/298/EEC for T2 rear-mounted ROPS does not!
Would it be better to mandate the fitting of seatbelts to retain operator in the ROPS protection zone during roll-over?
Would a minimum stability requirement reduce roll-over injuries?
Does the wide range of possible attached (mounted) implements mean ‘solo’tractor stability will have little relevance in subsequent use?
Is it better to focus upon tractor designs more likely to suffer from instability or be used on steep slopes?
T2 Narrow Track Tractors
T4.1 High-Clearance Tractors
T4.3 Low-Clearance Tractors
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Falling Object Protective Structures - FOPS
OECD Code 10 test procedure / performance requirement currently cited by 2010/52/EU
Falling objects from front or rear-mounted loaders believed to be the main risk in agriculture
FOPS are not mandatory for EC Type-Approval
But if provided they must conform
Are the current FOPS performance / test requirements adequate to protect the operator against such risks?
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Object Protective Structures - OPS
Intended to protect operator against flying / penetrating objects
2010/52/EU cites ISO 8084:2003 forestry vehicle performance requirement
But only need meet the requirement if provided
If used in forestry applications, 2010/52/EU requires tractor operators manual to provide information re.
Possible hazardsOptional equipment /guarding availableHow / where to mount such guardsLevel of FOPS protection provided
Is this sufficient for the risk?Probably?
Operators tend to install the protective devices needed to suit the application / implements being used
