AIS-018/2001

AUTOMOTIVE INDUSTRY STANDARD

Automotive Vehicles Speed Limitation Devices Specifications

PRINTED BY: THE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIA P. B. NO. 832. PUNE 411 004 ON BEHALF OF : AUTOMOTIVE INDUSTRY STANDARD COMMITTEE UNDER CENTRAL MOTOR VEHICLE RULES - TECHNICAL STANDING COMMITTEE SET-UP BY MINISTRY OF ROAD TRANSPORT & HIGHWAYS GOVERNMENT OF INDIA

July 2001

AIS-018/2001

Status

chart of the Standard to be used by the purchaser for updating the record

Sr. No.

Corrigenda.

Amendment

Revision

Date

Remark

Misc.

General remarks :

AIS-018/2001

Introduction
According to CMVR Government shall be governor conforming There are two Indian - 118, the transport vehicles as notified by the Central fitted by the operator of the vehicle with a speed to the specifications of Bureau of Indian Standard. standards on the subject viz.:

IS : 10144 - 1982 : Specifications for Electronic Speed Limiters for Diesel Vehicles. IS : 14382 - 1996 : Automotive Vehicles - Speed for installed requirements. - Limiters specifications

In order to update the standards and also to keep them aligned with EC, Automotive Industry Standards Committee (AISC) has formulated a procedure to evaluate the performance of speed limiting devices. It was considered that it will be better to merge both IS. This standard covers the speed limitation devices both as : a) Separate unit to be installed on a vehicle. b) As an add-on or on-board system built in the vehicle. The requirements cover the tests in the laboratory as well as on the road as installed on the vehicle. The members of AISC responsible for preparation of the standard is given in Annexure - I.

AIS-018/2001

Automotive Vehicles -Speed Limitation Devices - Specifications

1. SCOPE This standard specifies the requirements and methods of test of the Speed Limitation Device, both as (1) separate unit to be installed on the vehicle and (2) an add-on or on-board system built in the vehicle. The requirements cover the tests in the lab as well as on the road as installed on the vehicle. 2. 2.1 REFERENCES IS:10250-1982 "Specifications for Severities for Environmental Tests for Automotive Electrical Equipment" IS:9000 (Part V/Sec. 1 and 2) - 1981 "Basic Environmental Testing Procedures for Electronic and Electrical Items Damp Heat (Cyclic) Test" DEFINITIONS For the purpose of this standard : 3.1 Maximum Speed (Vmax) means the maximum speed reached by the vehicle on the first half period of the transient response curve, if any (refer Fig.1), if not, the cases as given in the Fig.2, Vset = Vmax. Set Speed (Vset) means the intended mean vehicle speed when operating in a stabilized condition. It shall be marked on the vehicle. Speed Limitation Device (Speed Limiter), hereinafter referred as SLD, means a device whose primary function is to control the fuel feed to the engine in order to limit the vehicle speed to the specified value. The purpose of the SLD is to limit the maximum road speed for vehicles to a specified value without affecting the other performance parameters of the vehicle in any manner. Stabilized Speed (Vstab), means the stabilized vehicle speed - average speed calculated over a minimum period of 20 s beginning 10 s after the set speed is achieved (refer Fig.1) and meeting the requirements specified in Cl. No. 5.7.3.4.2. Type of SLD means SLDs which do not differ with respect to the essential characteristics such as: make and type of the device. range of speed values at which the speed limitation device may be set. method used to control the fuel feed of the engine. 1

2.2

3.

3.2

3.3

3.4

3.5

AIS-018/2001 3.6 Unladen Mass means the mass of the vehicle in running order, including coolant, oils, fuel, tools and spare wheel on board, where applicable. In case of drive away chassis, the kerb weight of the drive away chassis will be considered in place of Unladen mass. Vehicle means any motor vehicle of category M3 with a maximum authorized mass exceeding 100 kN (10 tons) intended for use on the road having at least four wheels and a maximum design speed exceeding 25 km/h. Vehicle Type means vehicles, which do not differ in such essential respects as : make and type of the speed limitation system or speed limitation device , if any. range of speeds at which the limitation may be set, is within the ranges established for the tested vehicle. ratio of maximum engine power in unladen mass ( kerb weight in the case of drive away chassis ) is less than or equal. Calculated ratio of engine to vehicle speed in top gear at a given engine speed is less than that of the tested vehicle at the same engine speed in top gear.

3.7

3.8

4. 4.1

GENERAL REQUIREMENTS The speed limitation must be such that the vehicle in normal use must comply with the provisions of this standard. The SLD shall be so designed, constructed, assembled and fitted to the vehicle that it will perform satisfactorily, despite the vibrations to which it may be subjected. The SLD of the vehicle must be so designed, constructed and assembled as to resist corrosion and aging phenomena to which it may be exposed. The device should be so designed, constructed and assembled and fitted to the vehicle to make it maximum tamper proof and fail safe, against various factors such as disconnection / failure of various components e.g. power supply, speed sensor, mechanical actuator system, linkages etc. or any unauthorized modification and adjustment to the system. The limitation threshold must not, in any case, be capable of being increased or removed temporarily or permanently on vehicles in use. The inviolability shall be demonstrated to the testing agency with documentation analyzing the failure mode in which the system will be globally examined. The analysis shall show, taking into account the different states taken by the system, the consequences of a 2

4.2

4.3

AIS-018/2001 modification of the input or output states on the functioning, the possibilities of obtaining these modifications by failures or by tampering and possibility of their occurrence. The analysis level will be always to the first failure. 4.4 The speed limitation function or the SLD and the connections necessary for its operation except those essential for the running of the vehicle shall be protected from any unauthorized adjustments or the interruption of its energy supply by use of proper sealing devices and/or special tools. The speed limitation function or the SLD should work without causing interference with any other safety system of the vehicle. The speed limitation function or the SLD must be such that it does not affect the vehicles road speed if a positive action on the accelerator is applied when the vehicle is running at its set speed. The speed limitation function or the SLD must allow normal accelerator control for the purpose of gear changing. No malfunction or tampering shall result in an increase in engine power above that demanded by the position of the drivers accelerator. The speed limitation function shall be obtained regardless of the accelerator control used if there is more than one such control, which may be reached from the drivers seating position. The actuation force of the controls should not have a detrimental effect on the drivers efficiency or impose fatigue on the driver. The speed limiter function or the SLD shall operate satisfactorily in its electromagnetic environment without unacceptable electromagnetic disturbance for any other device in the environment. All components necessary for full function of the speed limitation or the SLD shall be energized whenever the vehicle is being driven. The device shall be fail safe and so designed that in the event of a failure of the speed limiter, the speed shall not be enhanced beyond the set speed limit and if there is any failure, there should be a positive indication to the driver. Further, the vehicle shall be capable of continuing to move at a reduced speed, even in the case of total failure/tampering of the speed limiter. The set speed shall be indicated on a plate in a conspicuous position in the drivers compartment of the vehicle. The device should provide functional check facility by which the set speed and functioning can be checked by the field and other concerned authorities. 3

4.5

4.6

4.7 4.8 4.9

4.10 4.11

4.12 4.13

4.14

4.15

AIS-018/2001 5. 5.1 TESTS OF SPEED LIMITATION DEVICE The SLD may be approved as a device alone when it meets the requirements of para 5.3 and 5.4 below. When it is intended for a specific vehicle model, it should meet the requirements of para 5.7 also. Five samples of SLD shall be provided - four samples for the performance and endurance test described in para 5.3 and 5.4 below and one sample as fitted on the vehicle for carrying out the tests prescribed in para 5.7 below. In the case of add-on or on-board system built in the vehicle, the involved system and its components should be provided separately for the performance and endurance tests. Performance Tests All the four samples shall be tested for performance as given below. Visual Examination The speed limiter shall be visually examined for workmanship, finish, marking and general requirements mentioned in para 4.0, pertaining to the components alone. 5.3.3 Functional Test and Power Consumption The speed limiter shall be connected to the rated voltage. The SLD shall be coupled to a suitable test rig and tested for its function viz. limiting the speed at the set value. The maximum current consumption is noted. The maximum current of each type of SLD shall not exceed the values specified by the manufacturer. 5.3.4 Operating Voltage Range The speed limiter shall operate satisfactorily over the following voltage:
Rated Voltage of Speed Performance Limit of Voltage

5.2

5.3 5.3.1 5.3.2

Limiter 24 12 6

Maximum 32 16 8

Minimum 22 11 5.5

5.4 5.4.1

Endurance Tests Endurance tests on SLD should be carried out as per the following procedure and conditions specified. The device should work satisfactorily during the tests and would meet the performance requirements as given in Cl. No. 5.3.3 after the test.

AIS-018/2001 5.4.2 Endurance Test at Ambient Temperature The SLD should be mounted on a test bench simulating the attitude and movement to simulate the vehicle conditions. The component should be tested for one lac cycles as described in Fig.3 at an ambient temperature of 30C 5C. 5.4.3 Endurance Test at High Temperature The component shall be mounted and tested as described in para 5.4.2 except that the component should be mounted in a chamber whose temperature is maintained at 55C 2C as per Clause 4.2 of IS : 10250- 1982 for 16 h. 5.4.4 Endurance Test at Low Temperature The component shall be mounted and tested as described in para 5.4.2 except that the component should be mounted in a chamber whose temperature is maintained at -10C 3C as per Clause 4.4 of IS:10250-1982 for 16 h. 5.4.5 Endurance Test with Damp Heat Cycling The component shall be mounted and tested as described in para 5.4.2 except that the component should be mounted in a chamber, whose environment is varied according to Damp Heat Cycle Test as per 1A Test Cycle of Variant 1 with upper temperature of 55C of IS: 9000 (Part V/Sec. 2)-1981 (Fig.2), for 6 damp heat cycles. 5.4.6 Endurance Test with Rapid Change of Temperature The component shall be mounted and tested as described in para 5.4.2 except that the component should be mounted in a chamber whose temperature is varied between -10C and 55C as per Group 2 Clause 4.5 of IS : 10250-1982, for 5 cycles of rapid change of temperature. 5.4.7 Endurance Test under Vibration The component shall be mounted on a table as per Clause 4.1 of IS : 10250-1982, with the following conditions : for engine mounted components, vibration should be provided in the frequency range of 10 Hz to 250 Hz with constant displacement of 0.75 mm upto a frequency of 57/62 Hz and a constant acceleration of 10 g above that frequency, for 1 h in each axis. for cabin mounted components, the test frequency is 10-55 Hz, constant displacement of 0.35 mm for 1 h in each axis.

AIS-018/2001 5.4.8 Endurance Test Salt Spray The components, exposed to the ambient road environment, shall be kept in a salt spray chamber with 5% concentration of sodium chloride and internal temperature of 35C 2C. The system should be tested as per Clause 4.8 of IS : 10250-1982 for 50 h. 5.5 5.5.1 Conditioning Tests : The device should be subjected to the following conditions and meet the performance requirements as given in the Cl. No.5.3.3 after the test. Conditioning with Dust The unit should be conditioned as per Clause 4.6 of IS : 10250-1982. 5.5.3 Conditioning with Contaminants The unit should be conditioned as per Clause 4.9 of IS : 10250-1982. 5.5.4 Conditioning with Water Spray The unit should be conditioned as per Clause 4.13 of IS : 10250-1982. 5.5.5 Drop and Topple Test The complete device should be subjected to drop and topple test as per Clause 4.10 of IS : 10250-1982 with a drop height of 200 mm and number of drops 6. 5.5.6 Bump Test The complete device should be subjected to bump test as per Clause 4.11 of IS : 10250-1982. 5.6 The distribution of the samples for the various tests are shown below:
Sr. No. Test 1 Endurance Tests Ambient Temperature High Temperature Low Temperature Damp Heat Cycles Rapid Change of Temperature Vibration Salt Spray Conditioning Tests Dust Contamination Water Spray Bump Drop and Topple Sample No. 2 3 4

5.5.2

1 2 3 4 5 6 7 8 9 10 11 12

* * * * * * * * * * * *

AIS-018/2001 5.7 5.7.1 Performance Tests on the Device as Fitted on the Vehicle SLD as installed on specified vehicle type can be approved as per choice of supplier by either of the following methods; mentioned in Cl. No. 5.7.3 or 5.7.4. The general requirements mentioned in Cl. No. 4 pertaining as fitted on the vehicle should be examined during the test. Measurement on Test Track Preparation of the Vehicle The device should be fitted on the vehicle to be approved. The settings of the engine of the test vehicle, particularly the fuel feed (carburetor or injection system) shall conform to the specification of the vehicle manufacturer. The tyres shall be bedded and the pressure shall be as specified by the vehicle manufacturer. The vehicle mass shall be unladen mass as declared by the manufacturer. 5.7.3.2 Characteristics of Test Track The test surface shall be suitable to enable stabilized speed to be maintained and free from uneven patches. Gradients shall not exceed 2% and vary by more than 1% excluding camber effects. 5.7.3.3 Wind Conditions The mean wind speed measured at a height atleast 1 m above ground shall be less than 6 m/s with gusts not exceeding 10 m/s. 5.7.3.4 Acceleration Test Method

5.7.2 5.7.3 5.7.3.1

5.7.3.4.1 The vehicle running at a speed, which is 10 km/h below the set speed, shall be accelerated as much as possible using a fully positive action on the accelerator controls. The action shall be maintained atleast 30 s after the vehicle speed has been stabilized. The instantaneous vehicle speed shall be recorded during the test in order to establish the curve of the speed versus the time and during the operation of the speed limiting function or of the SLD as appropriate. The accuracy of speed measurements shall be 1% and that of time measurements within 0.1s. 5.7.3.4.2 Acceptance Criteria for Acceleration Test The test shall be satisfactory if following conditions are met. The stabilized speed reached by the vehicle shall not exceed the set speed (Vstab Vset). However, a tolerance of 5% of the Vset value, or 5 km/h, whichever is higher is acceptable. 7

AIS-018/2001 Transient Response (Fig.1) After the set speed is reached first time, - The maximum speed shall not exceed the set speed , Vset by more than 5%. - The rate of change of speed shall not exceed 0.5 m/s2 when measured on a period greater than 0.1 s. - The stabilized speed conditions specified in para 3.4 shall be attained within 10 s of first reaching of the set speed Vset. Stabilized Speed (Fig.1) Vstab is the average speed calculated for a minimum time interval of 20s beginning 10s after first reaching Vset. When stable speed control has been achieved, Speed shall not vary by more than 4% of the set speed Vset or 2 km/h whichever is higher The rate of change of speed shall not exceed 0.2 m/s2 when measured on a period greater than 0.1 s. Acceleration tests shall be carried out and the acceptable criteria verified for each reduction ratio of gear allowing the speed to be exceeded. 5.7.3.5 Test Method at Steady Speed

5.7.3.5.1 The vehicle shall be driven at full acceleration till a steady speed is achieved, then shall be maintained at this speed for atleast 400 m. The test shall then be repeated in the opposite direction. The stabilized speed for the whole test is the mean of the two average speeds measured on both directions. The whole test including the calculation of the stabilization speed shall be carried out five times. The speed measurement shall be carried out with an accuracy of 1%, the time measurement with an accuracy of 0.1 s. 5.7.3.5.2 Acceptance Criteria for Steady Speed Test Tests are judged satisfactory if following conditions are fulfilled, None of the stabilization speeds Vstab obtained shall exceed set speed Vset. However, a tolerance of 5% of the Vset value or 5 km/h whichever is greater is acceptable. The gap between the extreme stabilization speeds obtained during the tests shall not exceed 3 km/h. Tests in steady speed shall be carried out and the acceptance criteria verified for each reduction gear ratio allowing, in theory, the speed limit to be exceeded. 8

AIS-018/2001 5.7.4 5.7.4.1 Tests on Chassis Dynamometer Characteristics of Chassis Dynamometer The equivalent inertia of the vehicle mass shall be reproduced on the chassis dynamometer with an accuracy of 10%. The speed of the vehicle shall be measured with an accuracy of 1%. The time shall be measured with an accuracy of 0.1s. 5.7.4.2 Acceleration Test Method

5.7.4.2.1 The power absorbed by the brake of the chassis dynamometer during the test shall be set to correspond with the vehicles resistance to progressive movement at the tested speed(s). This power may be established by calculation and shall be set to an accuracy of 10%. At the request of the manufacturers, the power absorbed may alternatively be set at 0.4 Pmax. (Pmax is the maximum power of the engine). The vehicle running at a speed which is 10 km/h below its set speed shall be accelerated to the maximum possible engine speeds by a fully positive action on the acceleration control. The action shall be maintained for at least 20 s, after the vehicle speed has been stabilized. The instantaneous vehicle speed shall be recorded during the test in order to establish the curve of the speed versus the time and during the operation of the speed limitation device. 5.7.4.2.2 Acceptance Criteria for the Acceleration Test The test shall be satisfactory if conditions of para 5.7.3.4.2 are met. 5.7.4.3 Test Method for Steady Speed Test

5.7.4.3.1 The vehicle shall be installed on the chassis dynamometer. The following acceptance criteria should be met for power absorbed by the chassis dynamometer varying progressively from the maximum power Pmax to a value equal to 0.2 Pmax. The speed of the vehicle shall be recorded in the full range of power defined above. The maximum speed of the vehicle shall be determined on this range. Test and record defined above shall be made five times. 5.7.4.3.2 Acceptance criteria for steady speed tests are judged satisfactory if the conditions of para 5.7.3.5.2 are fulfilled. NOTE : This standard is based on : 1 IS: 10144 - 1982: Specifications for Electronic speed limiters for diesel vehicles. IS: 14382 - 1996: Automotive Vehicles - Speed limiters specification for installed requirements.

AIS-018/2001 3 92/24/EEC : Council directive relating to speed limitation on-board systems of certain categories of vehicles. ECE R-89 "Uniform Provisions Concerning the Approval of : 1) Vehicle with regard to limitation of their maximum speed 2) Vehicle with regard to the installation of a speed limitation device of an approved type 3) Speed limitation device

10

AIS -018/2001

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AIS-018/2001
Annexure : ( See Introduction ) COMMITTEE COMPOSITION Automotive Industry Standards Committee

Chairman Shri. B. Bhanot Director The Automotive Research Association of India, Pune Members Shri. Alok Rawat Shri. V.C. Mathur

Representing
Ministry of Road Transport & Highways, New Delhi Department of Heavy Industry, Ministry of Industries & Public Enterprises, New Delhi Office of the Development Commissioner Small Scale Industries, Ministry of Industry, New Delhi. Bureau of Indian Standards, New Delhi. Vehicle Research & Development Establishment, Ahmednagar. Central Institute of Road Transport, Pune

Shri. G. S. Kashyab Shri. M.K. Bhat (Al ternate )

Shri. A. R. Gulati Shri. R. C. Sethi Shri. N. Karuppaiah ( Alternate ) Shri. D. G. Shirke Shri. P. C. Barjatia ( Alternate ) Shri. R. M. Shrivastava Shri. T. M. Balaraman Shri. I. V. Rao Shri. Z. A. Mujawar ( Alternate ) Shri. Vivek Adyanthaya (Alternate ) Shri. U. K. Kini ( Alternate ) Shri. T. C. Gopalan Shri. Vishnu Mathur Shri.K. N. D. Nambudiripad

Society of Indian Automobile Manufacturers. Society of Indian Automobile Manufacturers. Society of Indian Automobile Manufacturers. Society of Indian Automobile Manufacturers. Society of Indian Automobile Manufacturers. Society of Indian Automobile Manufacturers. Tractor Manufacturers Association, New Delhi. Automotive Components Manufacturers Association. Automotive Components Manufacturers Association

Member Secretary Mrs. Rashmi Urdhwareshe Sr.Assistant Director, The Automotive Research Association of India, Pune 12