Attachment J.5 TP-575-RR-02.pdf

TP-575-RR-02

JUL 8, 2015

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

49 CFR 575.106

TIRE FUEL EFFICIENCY INFORMATION PROGRAM (TFEIP)

Office of Vehicle Safety Compliance

NVS-220

1200 New Jersey Avenue, S.E.

Washington, DC 20590

OVSC LABORATORY TEST PROCEDURE

TIRE FUEL EFFICIENCY INFORMATION PROGRAM

Table of Contents

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. TEST DATA DISPOSITION

7. GOVERNMENT FURNISHED TEST ITEMS AND TEST SAMPLES

7.1 TEST SAMPLE IDENTIFICATION AND STORAGE

7.2 TIRE IDENTIFICATION AND MARKING

7.3 TEST TIRE HANDLING, STORAGE and DISPOSAL

7.4 MARKING AND TEST DATA REPORT SHEET

8. CALIBRATION OF TEST INSTRUMENTS

9. PHOTOGRAPHIC DOCUMENTATION

10. DEFINITIONS

11. PRETEST REQUIREMENTS

12. LAB ALIGNMENT TIRES (LATs)

13. TEST EXECUTION

13.1 TIRE MARKING AND VISUAL INSPECTION (TIRES A, and B)

13.2 TEST PROCEDURE / TIRE ROLLING RESISTANCE TEST

14. ALIGNMENT REQUIREMENT

14.1 ALIGNMENT LABORATORY REQUIREMENT

14.2 REQUIREMENT FOR ALIGNING CANDIDATE TIRES

14.3 ANALYSIS FOR EACH TEST PERFORMED

14.4 FREQUENCY OF ALIGNMENT

14.5 TIRE ALIGNMENT TEST DATA REPORT SHEETS

15. POST TEST REQUIREMENTS

16. REPORTS

16.1 FAILED TIRE PROCEDURE AND TIRE DISPOSITION

16.2 TIRE TEST DATA SHEETS

16.3 TIRE TEST REPORT COMPLETION PROCEDURES

16.4 TEST REPORT SUBMISSION

16.5 MONTHLY TEST PROGRAM STATUS REPORT

16.6 FINAL TEST REPORT FORMAT

Table of Figures

FIGURE 1 – TIRE ROLLING RESISTANCE MARKING AND TEST DATA REPORT SHEET

FIGURE 2 – ROLLING RESISTANCE TEST SHEET RADIAL TIRE

FIGURE 2B – ROLLING RESISTANCE TEST SHEET BIAS PLY TIRE

FIGURE 3 – LAB ALIGNMENT TIRE (LAT) ALIGNMENT FORM

FIGURE 4 – INITIAL REPORT OF ROLLING RESISTANCE TEST FAILURE & ANOMALY

REVISION CONTROL LOG

FOR OVSC LABORATORY TEST PROCEDURE

TP-RR, TIRE FUEL EFFICIENCY INFORMATION PROGRAM

TEST

PROCEDURE

49 CFR 575.106

DESCRIPTION

REV

No.

DATE AMENDMENT

EFFECTIVE

DATE

01 MARCH,

Original

Congressional requirement established in 49 CFR 575. This is the first TP to support this requirement; it is applicable to replacement tires covered under section 575.104(c), added tire disposition requirements

2 JULY

Original Applied the term rolling resistance throughout the document. Alignment procedure included. Laboratory test report sheet for both Radial and Bias ply tires.

1. PURPOSE AND APPLICATION

Section 575.106 of title 49, Code of Federal Regulations (CFR) requires tire manufacturers to rate the rolling resistance of their tires using a test procedure, developed by the International Organization for Standardization (ISO), ISO 28580:

“Tyre Rolling Resistance measurement method – Single point test and measurement result correlation – Designed to facilitate international cooperation and, possibly, regulation building.” The director of the Federal Register has approved the incorporation by reference of ISO 28580 in accordance with 5 U.S.C. 552(a) and 1 CFR Part 51. A copy of ISO 28580 may be obtained by contacting ISO at the following address, International Organization for Standardization (ISO) 1, ch. de la Voie-Creuse, Case postale 56 CH-1211 Geneva 20, Switzerland

Telephone: +41 22 749 01 11 Fax: +41 22 733 34 30 Web Site: http://www.iso.org.

By reference of ISO 28580, the Office of Vehicle Safety Compliance (OVSC) is providing this Laboratory Test Procedure (TP) for the use of its test labs (Independent labs) . The purpose of this TP is to provide guidelines for obtaining data in OVSC regulatory testing programs in a uniform data recording format, and for convenience both independent test labs and the agency lab will be termed “test lab” herein. This TP does not limit a laboratory’s testing methods to the procedures specified in this TP or specific brands of testing equipment. The test lab shall follow the ISO 28580 test procedures and all the testing parameters, tolerances, conditions, and equipment.

However, some of the test parameters, tolerances, conditions, and equipment, if differently specified in this TP, shall supersede those of which are specified in ISO 28580. Any deviation of the TP’s testing procedures, test parameters, tolerance, conditions, or recommended testing equipment must be approved by the Contracting Officer’s Representative (COR). Note: If testing is done at the agency’s lab, the Safety Compliance Engineer in charge of the program will serve as the equivalent of the COR herein. If testing is done at both independent test labs and the agency lab, the COR will coordinate both. In either case, COR will refer to either the Safety Compliance Engineer or COR, as applicable, herein.

The data obtained in an OVSC test are used to determine if the test specimen, a specific vehicle or item of motor vehicle equipment, meets the requirements specified in the TP. In some cases the TP does not include all of the various minimum performance requirements that are part of the aforementioned federal regulation or related regulations. Recognizing applicable test tolerances, the TP may specify tests conditions that are less severe than the minimum requirements specified in the regulation or the ISO test procedure.

If a test lab views any part to the TP to be in conflict with the associated regulation or ISO test procedure or observes deficiencies in the TP, the test lab shall advise the http://www.iso.org/

COR and resolve the discrepancy prior to the start of resumption of testing.

LEGAL NOTE: The OVSC Test Procedures are prepared for the limited purpose of disclosing to the public how the agency is directing its test lab and its own facility on how to conduct regulatory testing. The TPs are not rules, regulations or NHTSA interpretations regarding the regulation. The TPs are not intended to limit the requirements of any applicable FMVSS(s) or regulations. In addition the TPs may be modified by the OVSC at any time without notice, and the COR may direct or authorize test lab to deviate from these procedures, as long as the tests are performed in a manner consistent with the regulation itself and within the scope of the contract. TPs may not be relied upon to create any right or benefit in any person.

Therefore, compliance of a vehicle or an item of motor vehicle safety equipment is not guaranteed if the manufacturer limits its certification to tests described in the TP.

METRIC SYSTEM OF MEASUREMENT

As a general rule, performance parameters and test conditions in section 575.106 of title 49 CFR are specified primarily in metric units (viz., the International System of Units), so the use of the metric system of weights and measures is preferred. In this TP, metric values may be followed by English units (so-called US Customary Units), offset by parentheses, for reference purposes only (not necessarily equal). If test equipment is not available for direct measurement in metric units, the test laboratory shall calculate the exact metric equivalent by means of a conversion factor carried out to at least five significant digits before rounding consistent with the specified metric requirement. Metric units shall be used in the Final Test Reports.

2. GENERAL REQUIREMENTS

This test procedure applies to replacement and original equipment tires covered under section 575.104(c) of title 49 CFR. Each test tire shall meet the marking and performance requirements as specified in sections 571.109, 571.139, 574.5, 575.104, and 575.106 of title 49 CFR, as applicable.

This test procedure also applies to alignment tires used for alignment purposes under ISO 28580, and section 575.106 of tittle 49 CFR; see paragraph 12 of this TP.

3. SECURITY

The test lab shall provide appropriate security measures to protect the OVSC test specimens from unauthorized personnel during the entire testing program. The test lab is financially responsible for any acts of theft and/or vandalism that occur during the storage of test specimens. Any security problems that arise shall be reported by telephone to the COR within two working days after the incident with a letter containing details of the security problem will be sent to the COR within 48 hours.

The test lab shall protect and segregate the data that evolve from testing before and after each test. No information concerning the testing program shall be released to anyone except the COR, unless specifically authorized by the COR, the COR's

Branch or Division Chief, or the Contracting Officer.

NO INDIVIDUALS, OTHER THAN TEST LAB PERSONNEL, SHALL BE ALLOWED

TO WITNESS ANY REGULARTORY TEST UNLESS SPECIFICALLY AUTHORIZED

BY THE COR.

4. GOOD HOUSEKEEPING

The test lab shall maintain the entire testing area, test fixtures, and instrumentation in a neat and clean condition, with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices.

5. TEST SCHEDULING AND MONITORING

The test lab shall submit a test schedule to the COR prior to testing. Tests shall be completed as required in the contract. All testing shall be coordinated with the COR to allow monitoring by the COR or other OVSC personnel.

6. TEST DATA DISPOSITION

The test lab shall make all preliminary test data available to the COR within 4 hours after the test. Final test data, including digital printouts and computer generated plots (if applicable), shall be furnished to the COR in accordance with the contract schedule. Additionally, the test lab shall analyze the preliminary test results as directed by the COR. All backup data sheets, strip charts, recordings, plots, technicians’ notes, CD’s, etc., shall be retained by the test lab for a minimum of 3 years after conclusion of each delivery order, purchase order, etc. The COR shall direct final disposition at that time.

7. GOVERNMENT FURNISHED TEST ITEMS AND TEST SAMPLES

7.1 TEST SAMPLE IDENTIFICATION AND STORAGE

New Pneumatic Passenger Tires will either be provided to the test lab as Government Furnished Test Items (GFTI) test samples, or be procured by the test lab under tasking of a government contract. Receipt of these tires by the test lab will be acknowledged by emailing an Excel spreadsheet to the COR in the Office of Vehicle Safety Compliance (NVS-220). The spreadsheet shall include, at a minimum: the standard, manufacturer, brand, name, size, TIN (for each tire), number of tires received, date received, and any other relevant information.

NOTE: New tires without the manufacturer's Department of Transportation (DOT) certification symbol will not be reported on the spreadsheet. The laboratory will request disposition instructions from the COR for tires without the DOT symbol.

7.2 TIRE IDENTIFICATION AND MARKING

The test sample tires (GFTI), as received, will be marked and individually identified with a test number, which will remain with the tire and be correlated with the standard, laboratory, fiscal year, program, and test sequence. The tire shall be mounted so that the intended outboard sidewall will always be to the outside of the rim. The outside of the rim is the side that faces outboard when installed on a vehicle. During check-in, each tire shall be marked with its assigned test number by means of a paint stick or equivalent marking material.

7.3 TEST TIRE HANDLING, STORAGE and DISPOSAL

The laboratory will inspect the test tires when received to ascertain their acceptability for testing and will seek COR guidance in resolving abnormal conditions. The test tires shall be handled with care to avoid any damage or condition that may adversely affect test validity. It is incumbent upon the laboratory to ensure that no adverse change has occurred to the tire between the time of the inspection and test initiation.

The tires shall be kept in secured storage during any non-testing periods and properly stored and protected from grease, oil, miscellaneous solvents, and any surface dirt that could affect the results of the test program.

After being directed by the COR and in accordance with the contract, tested tires will be disposed of destructively to ensure the tires cannot be used on the road.

NOTE: At a minimum, each tire shall be disposed of in such a way that a tire cannot be repaired for highway use. Two methods that are approved are:

• Cut the tire in half through the tread area, such that both beads are still intact, but the tire is physically in two pieces. The tire changes from a single “O” shape with a “U” cross section to two separate “O” sections, separated circumferentially near the lowest point of the U.

• Cut completely through both beads in the same general location such that all tire material between the cuts has also been severed. The tire changes from an “O” shape with a “U” cross section to a “C” shape with the same cross section, except at the cut.

The test lab shall maintain records documenting their destructive disposition for the term of the contract, which shall be available upon request of the COR or Contracting Officer.

7.4 MARKING AND TEST DATA REPORT SHEET

The data report format for marking and rolling resistance test is depicted in FIGURE

1. The contract laboratory must follow to keep report format consistency as shown in FIGURE 1 for the report of test data unless approved otherwise by the COR.

TIRE CONSUMER INFORMATION PROGRAM

MARKING AND TEST DATA REPORT SHEET

TIRE MARKING DATA REPORT

1. Test Lab: __________________________ 2. Test Date: ________________________________

3. Lab Test No.: __________________________ 4. OVSC Report No.: __________________________

5. Tire Manufacturer: __________________________ 6. Tire Brand & Name: _________________________

7. Tire DOT TIN On 1IOS: __________________________ 8. Tire DOT TIN On 2OS: _______________________

9. TCIP Ratings: Traction______ Treadwear______ Rolling Resistance ____________

10. Tire Size Designation: __________________________ 11. Tire Construction: __________________________

12. Load Range/Index: __________________________ 13. Tube Type: _______________________________

14. Standard Load / Extra Load ____________________ 15. Tire Weight: _____ Kg / (_____ lbs)

16. Treadwear Indicators__________________________ 17. Tread Depth: _____ mm / (_____ in)

18. Carcass Cord Material/Plies: ________________________ 19. Belt Cord Material/Plies: _____________________

20. Number of Sidewall Plies: __________________________ 21. Number of Tread Plies: ______________________

22. Max Inflation Pressure: _____ kPa / (_____ psi) 23. Max Load Rating: _____ kg / (_____ lbs)

Remarks: _________________________________________________________________________________________

ROLLING RESISTANCE INFORMATION

1.Test Method3: __________________________ 2. Test Drum Wheel Diameter4 (m): ______________________

3.Test Rim Size: __________________________ 4. Tire Rim Material: __________________________________

5.Test Area Temperature @ Start Of Test: _____ oC / (_____ oF)

6.Test Area Temperature @ End Of Test: _____ oC / (_____ oF)

7.Load On The Tire Normal To The Test Drum Wheel Surface, 5Lm: _____ N / (_____ lbs)

8.Tire Dynamic Load Radius under steady state conditions, 5RL: ____m / (____in)

Tire Rolling Resistance Measurement:

1Intended Outboard Sidewall 2Opposite Sidewall 3see section 4 of ISO 28580 4see section 5.1 of ISO 28580 5Section 7.5 of ISO 28580

9. Manufacturer Reported Rolling Resistance Rating: _____

10. Laboratory Test Rolling Resistance Rating RRCalign: _____

Test Results (Passed/Failed) And Remarks: ________________________________________________________

Test Technician: _____________________________ Test Approved By: __________________________

FIGURE 1 – TIRE ROLLING RESISTANCE MARKING AND TEST DATA REPORT SHEET

Thermal Conditioning @ 25 (±5oC)

(Minimum 3 hr.)

Warm-Up Duration

(Minimum 30 min.)

Inflation Pressure Required

(kPa)

Inflation Pressure

Actual (kPa)

Maximum Load (Kg)

Load Actual

(N)

Speed Required

(kph)

Speed Actual (kph)

Rolling Resistance Coefficient Cr (N/kN)

Start End

Date

Time

Inflation Pressure

(kPa)

Ambient Temperature

( oC)

8. CALIBRATION OF TEST INSTRUMENTS

Before starting the test program, the test lab shall implement and maintain a measurement and test equipment calibration system in accordance with established calibration practices. Guidelines for setting up and maintaining such systems are described in ANSI/NCSL Z540-1-1994, Calibration System Requirements. The calibration system shall be set up and maintained as follows:

A. Standards for calibrating measurement and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability.

B. All measuring instruments and standards shall be calibrated by the test lab, or a commercial facility, against a higher order standard at periodic intervals of no more than 6 months and whenever the equipment or measuring devices are disturbed or suspect for any reason. Records showing the calibration traceability to the National Institute of Standards and Technology (NIST) shall be maintained for all measuring and test equipment.

C. All measuring equipment, test equipment, and measuring standards shall be labeled with the following information:

(1) Date of calibration

(2) Date of next scheduled calibration

(3) Name of the person who calibrated the equipment

D. A written, updated calibration procedure shall be provided by the test lab annually to the COR. This procedure shall include at a minimum the following information for all measuring and test equipment used to record all test parameters that are required to be automatically and continuously recorded (including time):

(1) Type of equipment, manufacturer, model number, etc.

(2) Measurement range

(3) Accuracy

(4) Calibration interval

(5) Type of standard used to calibrate the equipment (calibration traceability of the standard must be evident)

E. Records of calibrations for all measuring and test equipment shall be kept by the test lab in a manner that assures the maintenance of established calibration schedules. All such records shall be readily available for inspection when authorized by the COR. The calibration system will require acceptance by the COR before testing commences.

F. At a minimum, the measurement and test equipment calibration system will encompass:

(1) Equipment and devices to measure and/or record all test parameters required by this OVSC Laboratory Test Procedures manual.

(2) Alignment of the test tire axle with the test drum wheel axle. Maximum allowable misalignment is 10 minutes of arc for camber and toe-in.

(3) The roughness and runout of the test wheel. A test wheel shall not be used when surface roughness exceeds 0.0032 mm (0.000125 inch) or runout exceeds 0.25 mm (0.010 inch) Total Indicated Runout (TIR).

G. Each report will include a list of equipment used for testing, and for each item the manufacturer, the calibration schedule, the date of last calibration, the accuracy of the item and a column for remarks; see Test Equipment List and Calibration Information sample page in Appendix B.

9. PHOTOGRAPHIC DOCUMENTATION

Each final test report shall include color digital images of the test setup, which will include the test equipment and instrumentation used for each phase of testing; the minimum size of the digital images shall be 100 x 150 mm (4 x 6 inches). Each digital image shall include a title, presented either on the image or adjacent to it.

Pretest color digital images shall be taken of each tire that is subject to a rolling resistance test; there shall be one image of each tire side capturing the complete tire side. A 5-megapixel (minimum) digital camera shall be used with a resolution of at least 1800 x 1200 pixels. The digital images shall be saved until all tires of that make and model have completed all performance testing and marking inspection with passing results.

In the event of an apparent test failure or any test anomaly, the pretest digital images for that tire must be saved until deletion is directed by the COR. Further, digital images of each test failure occurrence shall be taken and saved until deletion is directed by the COR; images of the apparent failures shall show the point of failure from each point of view that can add significant detail. Also, the COR may direct that one or more of any of these digital images be included in the report and be provided in electronic format to OVSC; see paragraph 16 of this TP. If digital images of test tire failures are included in the report, they shall follow format established above.

10. DEFINITIONS

ACCEPTED REPORT

A tire test report validated by the Tire Test Data Management System or Tire Test Reporting System, certified as meeting NHTSA acceptance criteria and signed by the COR or representative.

ALPHA CHARACTER

A single alphabetical character from A to Z.

BEAD

That part of the tire made of steel wires, wrapped or reinforced by ply cords, that is shaped to fit the rim.

BEAD SEPARATION

A breakdown of bond between components in the bead area.

CAPPED INFLATION

Process of inflating the tire and allowing the inflation pressure to build up, as the tire is warmed up while running.

CARCASS

The tire structure, except tread and sidewall rubber.

CARCASS PLY

A ply that extends to the beads.

CANDIDATE MACHINE

Machine intended to measured new test tires (candidate tires) with alignment to the reference machine (NRLA).

CANDIDATE TIRE

A passenger car tire that would be used to be rated for fuel efficiency rolling resistance.

CHUNKING

The breaking away of pieces of the tread or sidewall.

CONTRACTING OFFICER’S REPRESENTATIVE (COR)

The designated OVSC official who is responsible for assuring laboratory compliance with contractual obligations. Also, for the purposes of this TP, when the agency is using its test lab only, the COR refers to the Safety Compliance Engineer in charge of the testing program.

CONTROL TIRE

One or more tires used by a test laboratory to monitor and control machine behavior as a function of time. At the discretion of each laboratory, a set of control tires may be used as a Lab Alignment Tire set after meeting the criteria set forth on Section 10.4 in ISO 28580

CORD

The strands that form the plies in the tire.

CRACKING

Any parting within the tread, sidewall, or innerliner of the tire extending to cord material.

EXTRA LOAD OR REINFORCED TIRE

A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire.

GROOVE

The space between two adjacent tread ribs.

INNERLINER

The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire.

INTENDED OUTBOARD SIDEWALL

(1) The sidewall that contains a whitewall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire; or

(2) The outward facing sidewall of an asymmetrical tire having a particular side that must always face outward when mounted on a vehicle.

LAB ALIGNMENT TIRES (LATs)

A set of two tires measured by both the NRAL machine and the candidate machine to perform machine alignment.

LOAD RATING

The maximum load a tire is rated to carry for a given inflation pressure.

MAXIMUM LOAD RATING

The load rating at the maximum permissible inflation pressure for that tire.

MAXIMUM PERMISSIBLE INFLATION PRESSURE

The maximum cold inflation pressure to which a tire may be inflated.

MEASUREMENT REPRODUCIBILITY σm

The statistic to measure the capability of a machine to measure rolling resistance; see ISO 28580, paragraph 3.12

MEASUREMENT RESULT CORRELATION

A set of rolling resistance measurements to be carried out on a regular time basis by separate laboratories in order to allow direct comparisons between their rolling resistance results.

MEASURING RIM

The rim on which a tire is fitted for physical dimension requirements.

NATIONAL ROLLING RESISTANCE ALIGNMENT LABORATORY (NRAL)

This is the reference machine laboratory for which candidate laboratories will be aligned

to. The NRAL shall comply with ISO 28580, clause 10.2 Conditions for Reference Machine.

NHTSA/OVSC

National Highway Traffic Safety Administration, Office of Vehicle Safety Compliance.

OPEN SPLICE

Any parting at any junction of tread, sidewalls, or innerliner that extends to cord material.

PASSENGER CAR (PC) TIRE

A passenger car (PC) tire means a tire intended for use on passenger cars, multipurpose passenger vehicles, and trucks, that have a gross vehicle weight rating (GVWR) of 10,000 pounds or less. These tires were formerly known as P-metric or P-Type tires.

PLY

A layer of rubber-coated parallel cords.

P-metric or P-Type TIRE

See Passenger Car Tire, above.

PNEUMATIC TIRE

A mechanical device made of rubber, chemicals, fabric, steel, or other materials, which, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load.

RADIAL PLY TIRE

A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90° to the centerline of the tread.

RIM

A metal support for a tire or a tire and tube assembly upon which the tire beads are seated.

ROLLING RESISTANCE: Fr

Loss of energy per unit of distance traveled; it is expressed in Newton-meter or simply Newtons.

ROLLING RESISTANCE COEFFICIENT: Cr or RRC

The ratio of the rolling resistance force to the load on the tire; it is a dimensionless number or in this TP expressed in the units of N/kN.

SIDEWALL

That portion of a tire between the tread and the bead.

SKIM TEST READING

Type of parasitic loss measurement in which the tire is kept rolling, with minimum slippage, while reducing the tire load to a level at which energy loss within the tire itself is virtually zero.

TEST RIM

The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire.

TEST SPECIMEN

A tire provided by OVSC for the purpose of testing.

TIRE EFFICIENCY

See Rolling Resistance, above.

TREAD

That portion of a tire that comes into contact with the road.

TREAD RIB

A tread section running circumferentially around a tire.

TREAD SEPARATION

Pulling away of the tread from the tire carcass.

TREADWEAR INDICATORS (TWI)

Projections of the compound material of the tire within the principal grooves designed to give a visual indication of the degree of wear of the tread.

11. PRETEST REQUIREMENTS

Each test lab is required to submit a detailed in-house test procedure to the COR before initiation the test program. The procedure must include a step-by-step description of the methodology to be used. The test lab’s test procedure shall contain a detailed check-off sheet and a complete listing of test equipment with makes and model numbers. The list of test equipment shall include instrument accuracy and calibration dates. There shall be no contradictions between the OVSC

Laboratory Test Procedure and the test lab’s in-house procedure without COR agreement.

Written approval of the in-house test procedure and all subsequent revision shall be obtained from the COR.

Prior to conducting a test, the test lab shall:

1. Verify COR approval of test lab’s in-house Test Procedures.

2. Verify the training of technicians for performance of this test.

3. Verify the calibration status of test equipment.

4. Review applicable revision of section 575.106 of title 49 CFR.

5. Set tire pressures according to the requirements of this TP.

11.1 TEST DETAILS

The contract laboratory shall follow test procedures and all the testing parameters, tolerances, conditions, and equipment as specified in ISO 28580 unless specified herein. The following subsections list and/or repeat some of the test parameters, tolerances, conditions, and equipment, which are important to this TP. These parameters, tolerances, conditions, and equipment, if differently specified in this TP, shall supersede those of which are specified in ISO 28580.

A. TEST RIMS

Tires tested in accordance with the requirements of section 575.106 of title 49 CFR must be tested on a rim designated as a test rim in contained in publications, current at the date of manufacturer of the tire or any later date, in at least one of these organizations:

• The Tire and Rim Association

• Japan Automobile Tire Manufacturers Association (JATMA)

• The European Tire and Rim Technical Organization practices (ETRTO)

• The Tyre & Rim Association of Australia

• Associacao Latino Americana do Pneus e Aros (Brazil), or

• South African Bureau of Standards.

(Alternate rim widths are not acceptable without authorization from the COR.)

A laboratory must obtain written approval from the COR to use a rim other than those specified. Prior to initial usage, the conformance dimensions of each test rim shall be verified by physical and appropriate measurement. Physical test rim measurements shall include the use of calibrated dial gage indicators;

ball gage; mandrel, diameter, and contour gages; and TRA sliding type gauge or equivalent. Test rim measurements shall include those for lateral and radial runout. The rim is to be measured at the bead seat area as defined by the Tire and Rim Association Year Book in effect at the time of the manufacture of the tire. Maximum allowable runout is 0.5 mm (0.02 in) for radial and 0.5 mm (0.02

in) for lateral. Each test rim shall be remeasured immediately after a tire failure on that rim. If no failures occur, each rim shall be measured at least every 25th mounting. A log of the number of the mountings and of these measurements shall be maintained and made available to the COR.

If, at any time, a rim dimension falls outside of its dimensional tolerances, that rim shall not be used for testing in this program. The material of the rim for either the LAT’s or candidate tires shall be of Aluminum or Steel. The test rims are to be identified numerically and assigned specifically to a tire so as to establish that the tire was tested on a specific rim. The test data sheet will indicate the rim used and the before and after test rim visual inspection results.

This visual inspection will include at least a check for obvious deformation of pilot hole, bolt holes, rim contours, cracks, etc. Test rim contours are interchangeable in terms of J, JJ and JK rim flange configuration 4, Test Logs.

A log of the progress of each test shall be entered routinely during the test on a form suited to the individual test laboratory. The COR must concur with the log format for maximum attainable standardization of all testing laboratories. This log shall be retained by the laboratory and made available upon request by the OVSC to support test report data. In the event of a failure of a test tire, the test lab shall follow the Failed Tire Procedure, see paragraph 16.1 of this TP.

B. TEST DATA LOSS

A test under this TP is not to be conducted unless all of the various test conditions specified in the applicable OVSC Laboratory Test Procedure have been met. Failure of a test lab to obtain the required test data and to maintain acceptable limits on test parameters in the manner outlined in the applicable OVSC Laboratory Test Procedure may require a retest at the expense of the test lab. The retest costs will include the cost of the replacement item of motor vehicle equipment and all costs associated with conducting the retest. The original test specimen used for the invalid test shall remain the property of OVSC, and the retest specimen shall remain the property of the test lab. If there is a test failure, the test lab shall retain the retest specimen until COR requests disposal. If there is no test failure, the test lab may dispose of the test specimen upon notification from the COR that the final test report has been accepted.

NHTSA's Contracting Officer Representative (COR) is the only NHTSA official authorized to notify the test lab that a retest is required. The retest shall be completed within 2 weeks after receipt of notification by the Contracting Officer that a retest is required. If a retest is conducted, no test report is required for the original test.

C. PERSONNEL PERFORMANCE

Personnel supervising and/or performing the test program shall be thoroughly familiar with the requirements, test conditions, equipment for the test to be conducted, and safety requirements.

NOTE: In the event of a tire being tested to this TP and not attaining the rolling resistance rating designated by the tire manufacturer, a formal post-test recalibration check of some critically sensitive test equipment and instrumentation may be required for verification of accuracy. In any event, the test lab is responsible for confirming that all equipment and instruments are in good working order prior to the next test. The necessity for each formal recalibration check, which must be traceable to NIST, will be at the COR's discretion. A routine post-test or daily calibration check, normally performed as part of the test lab's operating test procedures, where instruments are compared to physical parameters (e.g., ice bath for thermocouples) or by shunt calibrations (e.g., load cells), is not considered a formal recalibration check.

12. LAB ALIGNMENT TIRES (LATs)

12.1 THE TIRES

Each manufacturer of tires must have a set of LATs or control tires that will be used to align their machines and rate new tires for the TCIP under the regulation (49 CFR 575.106). The LAT’s set is measured by both the NRAL and the candidate lab for alignment. The test lab will record on a spreadsheet, at a minimum: the regulation (49 CFR 575.106), the purpose (alignment), manufacture, and brand name, size, tire serial or identification number (including date code). The LATs tire model may stay with the program for many years, yet, they are subject to change at any period of time as better LATs become available and are provided by the manufacturer. The set of LATs are as follows:

235/65R17 XL 108T Bridgestone Dueler A/T 694

195/55R16 87V Bridgestone Ecopia EP100

And/ Or

195/60R16 Bridgestone Ecopia PZ-X

225/80R15 Bridgestone Dueler A/T 694

These tires are available as a matched set of tires on the JATMA website at:

http://www.jatma.or.jp/labeling/contact.html where an English language link may be located for requesting a quote for purchasing such tires from Bridgestone Corporation.

Note: Alignment tires have not been certified to any United States of America (USA) tire safety standards, including FMVSS No. 109, 119, or 139, as such are neither intended nor authorized for use on USA roads.

12.2 TIRES HANDLING, STORAGE AND DISPOSAL

Each laboratory carries the responsibility to assure and inspect the test tire when received to ascertain their acceptability for testing and will seek customer guidance in resolving abnormal conditions. The test tires shall be handled with care to avoid any damage or condition that may adversely affect test validity. It is incumbent upon the laboratory to ensure that no adverse change has occurred to the tire between the time of the inspection and test initiation.

http://www.jatma.or.jp/labeling/contact.html

The tires shall be kept in secured storage during any non-testing periods and properly stored and protected from grease, oil, miscellaneous solvents, and any surface dirt that could affect the results of the test, or the performance of the tires.

13. TEST EXECUTION

Upon COR approval of the spreadsheet submitted to OVSC (See 7.1 TEST SAMPLE IDENTIFICATION AND STORAGE), the laboratory may begin testing in accordance with this TP and ISO 28580 test procedures.

13.1 TIRE MARKING AND VISUAL INSPECTION (TIRES A, and B)

Any tire tested for rolling resistance must comply with the tire marking requirements established in either paragraph S4.3 of FMVSS No. 109 or S5.5 of FMVSS No. 139. The marking data should be reported as shown in FIGURE

1. The test specimen tire A will be the primary testing tire for markings, rolling resistance test and visual inspection. Tire B will be use by the laboratory for additional testing if needed.

The tire and rim will be visually examined, inside and out, prior to assembly, and any rim found defective or questionable will not be used. Any tire defects noted shall be recorded in the remarks section of the test data report sheet, including any tread separation, sidewall, ply, cord, innerliner, or bead separation, chunking, broken cords, cracking or open splices. Notify the COR before testing if any of these defects are present.

Tire A will be used to perform the rolling resistance test per ISO28580 up to, but not more than, three times (A1, A2, A3). If the first attempt (A1) is successful then no further testing is required. If the first attempt fails to meet the standards set forth herein, then the test shall be repeated after a proper cooling of the test subject to the ambient temperature and re-inspection for any irregularities. If the second test (A2) results in another failure, then no further testing shall be required and the tire will be marked as not meeting the threshold for certification. If the second test is successful, then a third (A3) shall be performed after proper cooling and re-inspection of the test tire. Upon completion of the third test, the result of the third test will be the final result for the tire. If it is successful, then the tire shall be said to meet compliance with these standards. If the tire fails, please refer to section 16.1 of this TP to follow Failed Tire Procedure. If, at any time during the testing, Tire A suffers any damage or irregularity then Tire B shall be used, and the testing will continue from the last valid test result.

13.2 TEST PROCEDURE / TIRE ROLLING RESISTANCE TEST

The test lab shall follow the test procedures and all the testing parameters, tolerances, conditions, and equipment as specified in ISO 28580. However, some of the test parameters, tolerances, conditions, and equipment, if differently specified in this TP, shall supersede those of which are specified in ISO 28580. Please refer to FIGURE 2 or FIGURE 2B for rolling resistance test sheet.

A. AMBIENT TEMPERATURE

During the test, the ambient temperature shall be maintained at 25 oC. For ambient temperature other than 25 oC, the rolling resistance measurement should be corrected in accordance with section 9.2 of ISO 28580. The test results are unacceptable if the ambient temperature is lower than 20 oC or higher than 30 oC.

The test area temperature shall be recorded on the data sheet at the start, end of test and throughout the test.

B. TIRE TEST SPEED AND ACCURACY

Tire test speed, obtained at test drum wheel surface, shall be 80 kph and must be maintained at 80 kph, +0.0 kph, -0.4 kph for the torque method. For the force method, tire test speed must be maintained at 80 kph, +0.0 kph, -1.0 kph.

C. TIRE LOADING AND ACCURACY

Tire should be loaded at 80% of the maximum tire load capacity and should be maintained between + 0 N, -40 N or between +0.0% N, -1.0% N of 80% of maximum load capacity whichever has a greater negative lower limit value.

D. TIRE INITIAL INFLATION PRESSURE AND ACCURACY

The initial inflation pressure shall be kept 210 kPa, +6 kPa, -0 kPa for standard load tires and 250 kPa, +6 kPa, -0 kPa for reinforced or extra load tires.

During the test, capped inflation process should be used to allow the inflation pressure to build up for a more accurate representation of in-service behavior.

E. TEST DRUM WHEEL DIAMETER, WIDTH, AND SURFACE TEXTURE

Rolling resistance test shall be carried out using a drum wheel of 1.70 m in diameter and 80-grit textured drum wheel surface. The width of the test drum wheel surface must be wider than the test tire’s tread width. If the test is conducted using a drum wheel of diameter other than 1.7 m, a correlation adjustment must be made following the method of section 9.3 of ISO 28580.

Test tire shall be mounted on a test axle and press it against the outer face of a drum wheel having a diameter of 1.70 m ±1%.

F. CAPPED INFLATION PRESSURE

Tire pressure gradually rises during normal service condition. Using capped inflation procedure provides a more accurate representation of in-service behavior. Therefore, capped inflation should be used for the measurement of rolling resistance.

G. THERMAL CONDITIONING

Test tire should be inflated to the required pressure and placed in the thermal environment of the test location for a minimum of 3 hours with room temperature set at 25oC ideally, or maintain a temperature between 20oC to 30oC. Record the temperature and inflation pressure at the start and end of the thermal conditioning period. Thermal conditioning should be restarted from the beginning if the inflation pressure drops or raises more than 3 kPa at the end of thermal conditioning period. After thermal conditioning, the inflation pressure shall be adjusted to the required test pressure, and verified 10 minutes after the adjustment is made.

H. BREAK-IN PROCEDURE FOR BIAS PLY TIRES

Before starting tire rolling resistance testing to ISO 28580 on a bias ply passenger car tire, break in the tire by running it for 1 hour with the speed, loading, and inflation pressure specified as follows:

Speed:

80 kph, +0.0 kph, -0.4 kph for the torque method.

80 kph, +0.0 kph, -1.0 kph for the force method

Loading:

80% of the maximum tire load capacity and should be maintained between +0 N, -40 N or between +0.0% N, -1.0% N of 80% of maximum load capacity whichever has a greater negative lower limit value

Inflation Pressure:

210 kPa, +6 kPa, -0 kPa for standard load tires 250 kPa, +6 kPa, -0 kPa for reinforced or extra load tires

After the 1-hour break-in, allow the tire to cool for 2 hours and re-adjust to the required ISO 28580 test inflation pressure, and verify 10 minutes after the adjustment is made. After 1 hour break-in, bias ply tire should follow cooling period and the 30-minute warm-up procedure of ISO 28580. No break-in procedure is required for testing a radial tire.

I. WARM-UP DURATION

Each test tire should be warmed up on the rolling resistance machine for at least 30 minutes before any data acquisition.

To authenticate completion of the test, the technician who performed the test shall inscribe his initials and date of test completion in the spaces provided on the test sheet. The laboratory individual responsible for the tire test program shall inscribe his signature and date in the spaces provided.

J. POST TEST PRESSURE

After the rolling resistance test measurement or data acquisition is taken, the tire should be at rest for about 15 – 25 minutes. During the 15-25 minutes, a reading of pressure has to be taken; this is the posttest pressure reading. The posttest pressure reading should be greater than 95% of initial tire pressure.

Start End Start End Start End

Date

Time

Infl. Press (kPa)

Ambient Temp. (20°C to 30°C)

Test Load (Kg)

Test Speed (Kph)

Test cycle (km)

Total (Km)

Down Hours

Test cycle Hours

Total Hours

Technician

Down

Hours

If final Pressure < 95% kPa at additional 15-20 min.

kPa at additional 30-35 min.

kPa at additional 45-50 min.

Remarks

Final

Pressure after 15-25 min

Thermal

Conditioning

(25°C,+/-5°C)

3 hr min.

Re-adjust pressure

10 min

After

Conditioning

Warm Up

On Test Drum

30 min

Rolling Resistance

Test

FIGURE 2 – ROLLING RESISTANCE TEST SHEET RADIAL TIRE

Laboratory name, address, phone and fax

LABORATORY TEST REPORT

Date and time

TEST LOG – 575.106 Tire Rolling Resistance Test Radial Tire

Client Test No.: Tire No/ Rim No:

Lab Job#: Position No:

Client Tire No.: (DOT Tire Identification Number) Machine No:

Start End Start End Start End Start End Start End

Time

Infl. Press (kPa)

Ambient Temp. (20°C to 30°C)

Test Load (Kg)

Test Speed (Kph)

Test cycle (km)

Total (Km)

Down Hours

Test cycle Hours

Total Hours

Technician

Down

Hours kPa at additional 30-35 min.

Warm Up

On Test Drum

30 min

Rolling Resistance

Test kPa at additional 45-50 min.

Thermal

Conditioning

(25°C,+/-5°C)

3 hr min.

If final Pressure < 95%

Final

Pressure after 15-25 min

Re-adjust pressure

10 min

After

Conditioning

BIAS PLY

Break-In

1 hour

BIAS PLY

Cooling Period

2 hours kPa at additional 15-20 min.

Remarks

FIGURE 2B – ROLLING RESISTANCE TEST SHEET BIAS PLY TIRE

Laboratory name, address, phone and fax

LABORATORY TEST REPORT

Date and time

TEST LOG – 575.106 Tire Rolling Resistance Test Bias Ply

Client Test No.: Tire No/ Rim No:

Lab Job#: Position No:

Client Tire No.: (DOT Tire Identification Number) Machine No:

14. ALIGNMENT REQUIREMENT

14.1 ALIGNMENT LABORATORY REQUIREMENT

Under the Tire Fuel Efficiency Consumer Information Program (TFEIP) regulation (49 CFR 575.106), all manufactures of new pneumatic tires must align their testing candidate machines to the established National Rolling Resistance Alignment Laboratory (NRAL). In accordance with these requirements, the National Highway Traffic Safety Administration (NHTSA) published a final rule adopting international standard ISO 28580:2009(E) as the test procedure used for testing to obtain a tire rolling resistance ratings.

1. A candidate machine has to be aligned with the National Rolling Resistance

Alignment Laboratory, see ISO 28580 SECTION 10.5 Alignment Procedure. In order to be aligned to the NRAL, candidate labs (private industry, or independent laboratories) need to send their LAT’s or control tires that meet ISO 28580 requirements SECTION 10.4 Alignment Tyre Requirements, to the NRAL for alignment and get data as depicted in FIGURE 3. After measuring LAT’s at the NRAL, the tires need to also be measured in the laboratory’s candidate machine.

- During the alignment procedure (That is when measuring the set of LAT’s or Control tires), the lab must meet the requirement:

σm ≤ 0.075 N/kN

Where :

i im

, m

(1)

Note: if the case where, σm ≤ 0.075 N/kN is not met, the candidate laboratory shall calculate “n” number of measurements, as depicted in formula (2), taken as described in ISO 28580 Section 10.5.3.

e.g. if n = 4 and lab has already measured 3 times then the LAT’s must be run an additional of 1 more measurement.

mn (2)

Where : = 0.043 for passenger car and small truck and bus tires ( LI ≤ 121) n = number of measurements. Round to the next superior integer.

Re-calculate σm using all measurements repetitions on LAT’s or control tires to meet the requirement, σm ≤ 0.075 N/kN.

2. A candidate lab may proceed to derived the correlation equation using a linear regression method with aligned results where A and B are the correlation coefficients and are given in, Section 10.5.4 of ISO 28580:

RRCaligned = A x RRCcorrected + B (3)

Where: RRCaligned = Aligned rolling resistance coefficient (N/kN) RRCcorrected = Rolling resistance coefficient corrected for both temperature and drum (N/kN) A and B = Correlations coefficients

3. Correlations coefficients are derived from the NRAL lab testing and candidate laboratory testing. As an example, after testing is done on both NRAL and candidate laboratory then the following table is resultant:

Tire (LAT) x ( Candidate Lab ) * y (NRAL Lab)*

1 x1 y1

2 x2 y2

* average measurement

Find the slope:

xx yy slopeA

(4)

Find the intercept:

B = Y-intercept = 11 xAy (5)

14.2 REQUIREMENT FOR ALIGNING CANDIDATE TIRES

Once a candidate lab is aligned to the NRAL, a candidate laboratory or compliance laboratory may proceed to align candidate tires (test specimens for compliance purposes) to the requirements and procedures of ISO 28580 Section 10.3 Conditions for candidate machines.

1. A laboratory must perform and meet the requirement of the candidate machine in ISO 28580 on a monthly basis. Section 10.3, Conditions for candidate machine to monitor for drifting by using either sets of LAT’s and/or control tires.

- Every compliance lab or candidate lab must meet the requirement:

σm ≤ 0.075 N/kN σm ≤ 0.045 N/kN (For NAL)

Where:

i im

, m

(6)

Note: if the case where, σm ≤ 0.075 N/kN, is not met then the candidate laboratory shall calculate “n” number of measurements taken as described in ISO 28580 Section 10.3.3.

x n m (7)

Where : x = 0.075 for passenger car and small truck and bus tires ( LI ≤ 121) n = number of measurements. Round to the next superior integer. This is the number of measurements repetitions on candidate tires.

2. A laboratory or compliance lab may proceed to test for rolling resistance of a candidate tire or test specimen and get results for RRCcorrected. Rolling Resistance Test Sheet, FIGURE 2, may be used to record testing. Use equation (3) above to derived RRCaligned.

14.2.1 MONTHLY

a. The contractor shall perform monthly testing of the candidate machine using at least one matched set of Lab Alignment Tires (LATs), or a set of Control Tires. The tests and data analysis will be on each tire set. The test shall be performed to the requirements of ISO 28580, Section 10.3, Conditions for the Candidate Machine.

1. The approval criteria is for each tire set tested, σm < 0.075 N/kN with n ≥ 3;

see ISO 28580, Section 10.3 for σm and Section 10.3.3 for calculation of n

2. The contractor shall keep monthly records for average for each tire and σm for the set of tires tested in this section.

b. The contractor shall keep rolling resistance records for the average and σm which will consist of a simple averaging of each statistic. The rolling resistance records shall be saved for a period of 3 years.

c. Within 15 days after a calendar month, the contractor will report the monthly calculations of the average for both tires and σm for the set of tires.

d. Within four working days of the completion of the current monthly testing, the contractor will report if it is unable to meet the requirements of 14.2.1 of this section for the monthly test or the rolling resistance calculations. e.g. Lab experiencing machine drifting. The root cause and possible solution and/or countermeasure with lead time shall be reported to the COR.

14.2.2 DAILY

a. The contractor shall have daily control charting of the candidate machine.

b. It is primarily up to the contractor to determine what items shall be listed on the control chart, but these items, required by OVSC, should be considered a minimum requirement:

i. The name of the technician doing testing.

ii. Any anomalies to the machine, the tire or the test process.

iii. A remarks sections where the test technician or test engineer can enter detailed notes to document any problem, issue, question, or anomaly,

iv. The contractor shall also train the test technician and the test engineer on the purpose of the Remarks section and how to use it effectively in maintaining operation of the candidate machine.

v. A visual inspection of the test area and the candidate machine for irregularities should be done.

c. Periodic summary reports by the contractor…