ISO/FDIS 16750-3

Road vehicles — Environmental conditions and testing for electrical and electronic equipment — Part 3: Mechanical loads

Véhicules routiers — Spécifications d'environnement et essais de l'équipement électrique et électronique — Partie 3: Contraintes mécaniques

General Information

• Status: Not Published
• ICS: 43.040.10 - Electrical and electronic equipment
• Technical Committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
• Drafting Committee: ISO/TC 22/SC 32/WG 2 - Environmental conditions
• Current Stage: 5020 - FDIS ballot initiated: 2 months. Proof sent to secretariat
• Start Date: 03-Apr-2023
• Completion Date: 03-Apr-2023

Relations

• Revises: ISO 16750-3:2012 - Road vehicles — Environmental conditions and testing for electrical and electronic equipment — Part 3: Mechanical loads
• Effective Date: 23-Apr-2020

Standards Content (Sample)

DRAFT INTERNATIONAL STANDARD
ISO/DIS 16750-3.2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:
2023-03-01 2023-04-26
Road vehicles — Environmental conditions and testing for
electrical and electronic equipment —
Part 3:
Mechanical loads

Véhicules routiers — Spécifications d'environnement et essais de l'équipement électrique et électronique —

Partie 3: Contraintes mécaniques
ICS: 43.040.10
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
THEREFORE SUBJECT TO CHANGE AND MAY
This document is circulated as received from the committee secretariat.
NOT BE REFERRED TO AS AN INTERNATIONAL
STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS
BEING ACCEPTABLE FOR INDUSTRIAL,
TECHNOLOGICAL, COMMERCIAL AND
USER PURPOSES, DRAFT INTERNATIONAL
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/DIS 16750-3.2:2023(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
PROVIDE SUPPORTING DOCUMENTATION. © ISO 2023
---------------------- Page: 1 ----------------------
ISO/DIS 16750-3.2:2023(E)
DRAFT INTERNATIONAL STANDARD
ISO/DIS 16750-3.2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:
Road vehicles — Environmental conditions and testing for
electrical and electronic equipment —
Part 3:
Mechanical loads

Véhicules routiers — Spécifications d'environnement et essais de l'équipement électrique et électronique —

Partie 3: Contraintes mécaniques
ICS: 43.040.10
COPYRIGHT PROTECTED DOCUMENT
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
© ISO 2023
THEREFORE SUBJECT TO CHANGE AND MAY
This document is circulated as received from the committee secretariat.

All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may

NOT BE REFERRED TO AS AN INTERNATIONAL

be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on STANDARD UNTIL PUBLISHED AS SUCH.

the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below

IN ADDITION TO THEIR EVALUATION AS

or ISO’s member body in the country of the requester. BEING ACCEPTABLE FOR INDUSTRIAL,

TECHNOLOGICAL, COMMERCIAL AND
ISO copyright office
USER PURPOSES, DRAFT INTERNATIONAL
CP 401 • Ch. de Blandonnet 8
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
CH-1214 Vernier, Geneva
POTENTIAL TO BECOME STANDARDS TO
Phone: [phone]
WHICH REFERENCE MAY BE MADE IN
Reference number
Email: [e-mail]
NATIONAL REGULATIONS.
Website: www.iso.org ISO/DIS 16750-3.2:2023(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
Published in Switzerland
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
© ISO 2023 – All rights reserved
PROVIDE SUPPORTING DOCUMENTATION. © ISO 2023
---------------------- Page: 2 ----------------------
ISO/DIS 16750-3.2:2023(E)
Contents

Foreword ........................................................................................................................................................................................... vii

1  Scope ......................................................................................................................... .................................................................... 1

2  Normative references .......................................................................................................... .................................................. 1

3  Terms and definitions ......................................................................................................... .................................................. 2

4  Tests and requirements ........................................................................................................ ................................................ 2

4.1  Vibration ..................................................................................................................... ....................................................... 2

4.1.1  Testing conditions during the vibration test .................................................................................. .......... 2

4.1.2  Test Ia - Passenger car, combustion engine, small and lightweight DUT .................................. 10

4.1.3  Test II — Passenger car, gearbox attached to a combustion engine, small and lightweight

DUT 13

4.1.4  Test VI — Commercial vehicle, combustion engine and gearbox, small and lightweight

DUT 15

4.1.5  Test XIII — Passenger car, hybrid-electric powertrain, combustion engine and gearbox,

large and heavy DUT ........................................................................................................................................................... 19

4.1.6  Test XV — Passenger car, driving electric motor ................................................................................ 23

4.1.7  Test XX — Commercial vehicle, driving electric motor ..................................................................... 25

4.1.8  Test IV — Passenger car, sprung masses (vehicle body), small and lightweight DUT ......... 27

4.1.9  Test VII — Commercial vehicle, sprung mass (vehicle body), small and lightweight DUT 29

4.1.10  Test XIV — Hybrid-electric/fully-electric passenger car, sprung mass (vehicle body), large

and heavy DUT....................................................................................................................................................................... 30

4.1.11  Test XVI — Hybrid-electric/fully-electric commercial vehicle, sprung mass (vehicle body),

large and heavy DUT ........................................................................................................................................................... 32

4.1.12  Test V — Passenger car, unsprung mass (wheel, wheel suspension), small and lightweight

DUT 34

4.1.13  Test IX — Commercial vehicle, unsprung mass, small and lightweight DUT ........................... 35

4.1.14  Test VIII — Commercial vehicle, decoupled cab .................................................................................. 36

4.1.15  Test III — Passenger car, flexible plenum chamber ........................................................................... 38

4.1.16  Test XI — Passenger car, solid intake manifold ................................................................................... 39

4.1.17  Test Ib – Rotating machines ......................................................................................................................... 41

© ISO 2023 – All rights reserved
iii
---------------------- Page: 3 ----------------------
ISO/DIS 16750-3.2:2023(E)

4.1.18  Test XII — Passenger car, exhaust pipe ................................................................................................... 45

4.1.19  Test X — Passenger car, components on fuel rail (gasoline engine with GDI-system) ....... 49

4.2  Mechanical shock ........................................................................................................................................................ 51

4.2.1  Shock I — Test for devices in or on doors and flaps on passenger cars..................................... 51

4.2.2  Shock II — Test for devices on rigid points on the body and on the frame .............................. 52

4.2.3  Shock III — Test for devices in or on the gearbox ............................................................................... 53

4.3  Free fall ........................................................................................................................................................................... 53

4.3.1  Purpose ................................................................................................................................................................. 53

4.3.2  Test ......................................................................................................................................................................... 54

4.3.3  Selection of drop height ................................................................................................................................. 55

4.3.4  Requirements ..................................................................................................................................................... 55

4.4  Surface strength/scratch and abrasion resistance ....................................................................................... 56

4.4.1  Purpose ................................................................................................................................................................. 56

4.4.2  Test Method ......................................................................................................................................................... 56

4.4.3  Requirements ..................................................................................................................................................... 56

4.5  Gravel bombardment ................................................................................................................................................ 56

4.5.1  Purpose ................................................................................................................................................................. 56

4.5.2  Test method ......................................................................................................................................................... 56

4.5.3  Requirements ..................................................................................................................................................... 56

5  Code letters for mechanical loads ................................................................................................................................. 57

6  Documentation ...................................................................................................................................................................... 58

Annex A (informative) Guidelines for the development of test profiles for vibration tests .......................... 59

A.1  Scope ..................................................................................................................................................................................... 59

A.2  General ................................................................................................................................................................................. 59

A.3  Average control method ............................................................................................................................................... 63

A.4  Method for determining the vibration profile and test duration on/in powertrain ........................... 64

A.4.1 General aspects regarding test duration ........................................................................................................... 64

© ISO 2023 – All rights reserved
---------------------- Page: 4 ----------------------
ISO/DIS 16750-3.2:2023(E)

A.4.2 Test duration, example for ICE without any electric propulsion ............................................................ 65

A.4.3 Test duration, example for PHEVs ....................................................................................................................... 68

A.4.4 Verification of load in combustion engine speed distribution ................................................................. 70

A.4.4.1  Procedure ....................................................................................................................................................................... 70

A.4.4.1.1  Measurement of acceleration levels with a combustion engine speed increase on the chassis

dynamometer .................................................................................................................................................................................. 71

A.4.4.1.2  Determination of the load distribution from the measured time history (cycle counting

method) 71

A.4.4.1.3  Analysis of the number of cycles in the classed acceleration levels and combustion engine

speeds 72

A.4.4.1.4  Verification of the dominant load from the high combustion engine speed range .................... 73

A.4.5 Sources for vibration in an SoR profile for powertrain-mounting ......................................................... 74

A.5  Method for determining the vibration profile and test duration for DUT mounted on the body .. 75

A.5.1 General ............................................................................................................................................................................ 75

A.5.1.1  Enveloping vibration profile .................................................................................................................................. 75

A.5.1.2  Test duration ................................................................................................................................................................ 75

A.5.2 Verification of the shortened test duration using fatigue calculation .................................................. 76

A.5.2.1  General ............................................................................................................................................................................ 76

A.5.2.2  Procedure ....................................................................................................................................................................... 76

A.5.2.3  Test parameters for random vibration .............................................................................................................. 77

A.5.2.4  Acceleration distributions of random vibration test and vehicle driving ........................................... 77

A.5.2.5  Comparative verification between random test and driving stress ...................................................... 79

A.5.2.6  Calculation of the fatigue limits ............................................................................................................................ 79

A.6  Test duration for a sinusoidal test not governed by an engine speed distribution ............................. 82

A.7  Test duration with an infinite-life approach for car-body-mounted DUTs ............................................. 83

A.8  The explanation for Basquin model ......................................................................................................................... 86

A.8.1 General ............................................................................................................................................................................ 86

A.8.2 Outline ............................................................................................................................................................................. 86

A.8.3 Calculation example ................................................................................................................................................... 86

© ISO 2023 – All rights reserved
---------------------- Page: 5 ----------------------
ISO/DIS 16750-3.2:2023(E)

A.9  Vibration test profiles developed in ISO 19453 .................................................................................................. 89

A.9.1 Background ................................................................................................................................................................... 89

A.9.2 Vibration profiles for Test XIII (Passenger car, hybrid-electric powertrain, large and heavy

DUT) 89

A.9.2.1  Sine on random vibration test ............................................................................................................................... 89

A.9.2.2  Random vibration test .............................................................................................................................................. 93

A.9.3 Vibration profiles for Test XIV (Hybrid-electric/fully electric passenger car, sprung mass

(vehicle body), large and heavy DUT) ................................................................................................................................... 95

A.9.4 Vibration profiles for Test XV (Passenger car, driving electric motor) ................................................ 96

Figure A.19 — PSD of acceleration versus frequency ..................................................................................................... 97

Table A.20 — Values for PSD and frequency ...................................................................................................................... 97

Annex B (informative) Recommended mechanical requirements for equipment depending on the

mounting location .......................................................................................................................................................................... 99

Annex C (informative) Guidelines for shaker testing of starter motors, alternators and similar DUTs 101

C.1  Test setup for Alternators and Integrated Starter Generators .................................................................. 101

C.2  Test setup for starter motors .................................................................................................................................. 102

C.3  Vibration test profile validation process for dynamically coupled, engine mounted components

103

Annex D (informative) Guidelines for free fall testing ............................................................................................... 108

D.1  Best practice example for choice of DUT orientation .................................................................................... 108

D.2  Further information on the drop height ............................................................................................................. 109

D.3  Characteristics of the impact surface ................................................................................................................... 109

Annex E (informative) 3D vibration testing for automotive components ......................................................... 111

E.1  Motivation ....................................................................................................................................................................... 111

E.2  Profile derivation for random vibration tests .................................................................................................. 111

E.3  Difference in uniaxial and multiaxial fatigue for body parts under realistic random excitation 112

Bibliography .................................................................................................................................................................................. 114

© ISO 2023 – All rights reserved
---------------------- Page: 6 ----------------------
ISO/DIS 16750-3.2:2023(E)
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national

standards bodies (ISO member bodies). The work of preparing International Standards is normally

carried out through ISO technical committees. Each member body interested in a subject for which a

technical committee has been established has the right to be represented on that committee.

International organizations, governmental and non-governmental, in liaison with ISO, also take part in

the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all

matters of electrotechnical standardization.

The procedures used to develop this document and those intended for its further maintenance are

described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the

different types of ISO documents should be noted. This document was drafted in accordance with the

editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of

any patent rights identified during the development of the document will be in the Introduction and/or

on the ISO list of patent declarations received (see www.iso.org/patents).

Any trade name used in this document is information given for the convenience of users and does not

constitute an endorsement.

For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and

expressions related to conformity assessment, as well as information about ISO's adherence to the

World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see

www.iso.org/iso/foreword.html.

This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 32,

Electrical and electronic components and general system aspects.

This fourth edition cancels and replaces the third edition (ISO 16750-3:2012), which has been

technically revised.
The main changes compared to the previous edition are as follows:
‐ Integrating and harmonizing content from ISO 19453-3:2018;
‐ Distinction between small and lightweight versus large and heavy DUTs;

‐ Revising vibration profiles where necessary due to extended datasets of and experience from

vehicle measurements;
‐ New vibration test for rotating machines on combustion engines and Annex C;
‐ New vibration tests for hybrid-electric/fully-electric commercial vehicles;
‐ Guided fall test description and Annex D;
‐ Annex E as guidance for 3D shaker testing;

‐ Test order appearing in the document has been changed for a logical grouping depending on

test type, however test numbers have been kept for backwards compatibility.
© ISO 2023 – All rights reserved
vii
---------------------- Page: 7 ----------------------
ISO/DIS 16750-3.2:2023(E)

A list of all parts in the ISO 16750 series can be found on the ISO website.Any feedback or questions on

this document should be directed to the user’s national standards body. A complete listing of these

bodies can be found at www.iso.org/members.html.
© ISO 2023 – All rights reserved
viii
---------------------- Page: 8 ----------------------
DRAFT INTERNATIONAL STANDARD ISO/DIS 16750-3.2:2023(E)
1 Road vehicles — Environmental conditions and testing for
2 electrical and electronic equipment— Part 3: Mechanical
3 loads
4 1 Scope

5 This document applies to electric and electronic systems and components for vehicles including electric

6 propulsion systems and components with maximum working voltages according to voltage class B. It

7 describes the potential environmental stresses and specifies tests and requirements recommended for

8 the specific mounting location on/in the vehicle.
9 This document describes mechanical loads.

10 This document is not intended to apply to environmental requirements or testing for systems and

11 components of motorcycles and mopeds.

12 Systems and their components released for production, or systems and their components already under

13 development prior to the publication date of this document, can be exempted from fulfilling the changes

14 in this edition compared to the previous one.
16 2 Normative references

17 The following documents are referred to in the text in such a way that some or all of their content

18 constitutes requirements of this document. For dated references, only the edition cited applies. For

19 undated references, the latest edition of the referenced document (including any amendments) applies.

20 ISO 16750-1:2023, Road vehicles — Environmental conditions and testing for electrical and electronic

21 equipment — Part 1: General

22 ISO 16750-4:2023, Road vehicles — Environmental conditions and testing for electrical and electronic

23 equipment— Part 4: Climatic loads

24 IEC 60068-2-6, Environmental testing — Part 2‐6: Testing, Test Fc: Vibration (Sinusoidal)

25 IEC 60068-2-14, Environmental testing — Part 2‐14: Tests — Test N: Change of temperature

26 IEC 60068-2-27, Environmental testing — Part 2‐27: Tests — Test Ea and guidance: Shock

27 IEC 60068-2-31, Environmental testing — Part 2‐31: Tests — Test Ec: Rough handling shocks, primarily

28 for equipment‐type specimens

29 IEC 60068-2-47:2005, Environmental testing ‐ Part 2‐47: Test ‐ Mounting of specimens for vibration,

30 impact and similar dynamic tests
© ISO 2023 – All rights reserved
---------------------- Page: 9 ----------------------
ISO/DIS 16750‐3:2022(E)
ISO/DIS 16750-3.2:2023(E)

31 IEC 60068-2-64, Environmental testing — Part 2‐64: Tests — Test Fh: Vibration, broadband random and

32 guidance

33 IEC 60068-2-80, Environmental testing — Part 2‐80: Tests — Test Fi: Vibration — Mixed mode

34 UL 969, Standard for Marking and Labeling Systems, 5th edition, 2017

35 ISO 20567-1:2017, Paints and varnishes — Determination of stone‐chip resistance of coatings — Part 1:

36 Multi‐impact testing
38 3 Terms and definitions

39 For the purposes of this document, the terms and definitions given in ISO 16750-1 apply.

40 ISO and IEC maintain terminology databases for use in standardization at the following addresses:

41 — ISO Online browsing platform: available at https://www.iso.org/obp
42 — IEC Electropedia: available at https://www.electropedia.org/
44 4 Tests and requirements
45 4.1 Vibration
46 4.1.1 Testing conditions during the vibration test
47 4.1.1.1 General

48 The vibration test methods specified consider various levels of vibration severities applicable to on-

49 board electrical and electronic equipment. The customer and the supplier should choose the test

50 method, environmental temperature and vibration parameters depending on the specific mounting

51 location.

52 A clear dependence of the typical vibration load on the size and mass of the DUT is evident from vehicle

53 measurements. This applies to all mounting locations due to dynamic system coupling. That is why in

54 this document a distinction is made between small and lightweight E/E components (typically < 2 kg,

55 unless stated otherwise in the individual test description, e.g. sensors, ECUs or fuel injection

56 equipment), mostly belonging but not limited to ICE vehicles, and much larger and heavier components

57 (typically ≥ 2 kg, unless stated otherwise in the individual test description, e.g. electric motors, inverters,

58 DC/DC converters or alternators), mostly belonging but not limited to electric powertrains in electric

59 propulsion vehicles. In each application the applicability of the intended vibration profile should be

60 verified with a vehicle measurement. See a mass classification example in ISO 16750-1:— , Annex C. For

61 further information and guidance please refer to Table 38 (code letters).

Fourth edition under preparation. Stage at the time of publication: ISO/DIS 16750-1:2022.

© ISO 2022 – All rights reserved
© ISO 2023 – All rights reserved
---------------------- Page: 10 ----------------------
ISO/FDIS 16750‐3:2022(E)
ISO/DIS 16750-3.2:2023(E)

62 The following basic idea of environmental test methods is expressed in Reference [4], Foreword.

63 When applied properly, the environmental management and engineering processes described in this

64 document can be of enormous value in generating confidence in the environmental worthiness and

65 overall durability. However, it is important to recognize that limitations inherent in laboratory testing

66 make it imperative to use proper caution and engineering judgment when extrapolating these

67 laboratory results to results that can be obtained under actual service conditions. In many cases, real

68 world environmental stresses (singularly or in combination) cannot be duplicated practically or reliably

69 in test laboratories. Therefore, users of this document should not assume that a system or component

70 that passes laboratory tests of this document would also pass field/fleet verification trials.

71 The specified values are the best estimation that can be obtained up to the moment when results from

72 measurements in the vehicle are received, but they do not replace a vehicle measurement.

73 The specified values apply to direct mounting in defined mounting locations. The specified vibration

74 profiles apply to direct mounting in defined mounting locations. Since the use of an installation support

75 (e.g. mounting bracket) can influence test vibration loads on the shaker to be much higher or much

76 lower than actual vehicle loads, in principle, each vibration test should be carried out with only DUT

77 itself. If using an installation support, the applied loads on the shaker should be checked to reproduce

78 the actual vehicle loads as realistically as possible.

79 Carry out the vibration with the DUT rigidly mounted on a vibration table for reasons of comparability

80 and reproducibility (see also clauses 5 and 6 in IEC 60068-2-47:2005). If using a bracket is technically

81 unavoidable in order to fix the DUT to the shaker instead of a r
...