Cycles - Components and assemblies used in bicycles - Innovative requirements and test methods

The purpose of this document is to provide innovative requirements and test methods applicable to any components and assemblies of any category of bicycles (city, trekking, MTB, young adult and racing). Its aim is to provide technical solutions that reduce the risk of component failure and rider injury during the specified use of such bicycles.
This document makes reference to current "state of the art" standards in the field of bicycles, agreed at CEN level through the publication of the EN ISO 4210 series of standards. Therefore, the requirements and tests proposed in this document are intended to be read and applied in accordance with the appropriate EN ISO 4210 standard.
NOTE   The tests described in this document refer in places to clause numbers from the applicable EN ISO 4210 series.

Fahrräder - Verbundwerkstoffe für Fahrräder - Neue Spezifische Prüfverfahren für aus Verbundwerkstoffe hergestellte Komponenten

Cycles - Composants et assemblages utilisés dans les bicyclettes - Exigences et méthodes d'essai innovantes

Kolesa - Sestavni deli in sklopi za kolesa - Inovativne zahteve in preskusne metode

General Information

Status
Published
Public Enquiry End Date
24-Mar-2021
Publication Date
28-Jun-2021
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
14-Jun-2021
Due Date
19-Aug-2021
Completion Date
29-Jun-2021

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SLOVENSKI STANDARD
SIST-TP CEN/TR 17653:2021
01-september-2021

Kolesa - Sestavni deli in sklopi za kolesa - Inovativne zahteve in preskusne metode

Cycles - Components and assemblies used in bicycles - Innovative requirements and

test methods

Fahrräder - Verbundwerkstoffe für Fahrräder - Neue Spezifische Prüfverfahren für aus

Verbundwerkstoffe hergestellte Komponenten
Ta slovenski standard je istoveten z: CEN/TR 17653:2021
ICS:
43.150 Kolesa Cycles
SIST-TP CEN/TR 17653:2021 en,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
SIST-TP CEN/TR 17653:2021
---------------------- Page: 2 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653
TECHNICAL REPORT
RAPPORT TECHNIQUE
June 2021
TECHNISCHER BERICHT
ICS 43.150
English Version
Cycles - Components and assemblies used in bicycles -
Innovative requirements and test methods
Fahrräder - Verbundwerkstoffe für Fahrräder - Neue
Spezifische Prüfverfahren für aus Verbundwerkstoffe
hergestellte Komponenten

This Technical Report was approved by CEN on 30 May 2021. It has been drawn up by the Technical Committee CEN/TC 333.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 17653:2021 E

worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
Contents Page

European foreword ....................................................................................................................................................... 3

1 Scope .................................................................................................................................................................... 4

2 Normative references .................................................................................................................................... 4

3 Terms and definitions ................................................................................................................................... 4

4 Frames designed for disc brake ................................................................................................................. 4

4.1 Background ....................................................................................................................................................... 4

4.2 Test methods .................................................................................................................................................... 5

4.2.1 Rear brake mount tests ................................................................................................................................. 5

4.2.2 Static rear brake torque test ....................................................................................................................... 5

4.2.3 Rear brake mount fatigue test .................................................................................................................... 5

5 Fork made of composite materials designed for disc brakes ......................................................... 7

5.1 General ................................................................................................................................................................ 7

5.2 Test methods .................................................................................................................................................... 7

6 Wheel impact test ............................................................................................................................................ 9

6.1 Background ....................................................................................................................................................... 9

6.2 Requirements ................................................................................................................................................... 9

6.3 Test methods ................................................................................................................................................. 10

7 Front mudguard ............................................................................................................................................ 12

7.1 Background .................................................................................................................................................... 12

7.2 Requirements ................................................................................................................................................ 12

---------------------- Page: 4 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
European foreword

This document (CEN/TR 17653:2021) has been prepared by Technical Committee CEN/TC 333 “Cycles”,

the secretariat of which is held by UNI.

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

patent rights. CEN shall not be held responsible for identifying any or all such patent rights.

---------------------- Page: 5 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
1 Scope

The purpose of this document is to provide innovative requirements and test methods applicable to any

components and assemblies of any category of bicycles (city, trekking, MTB, young adult and racing). Its

aim is to provide technical solutions that reduce the risk of component failure and rider injury during the

specified use of such bicycles.

This document makes reference to current “state of the art” standards in the field of bicycles, agreed at

CEN level through the publication of the EN ISO 4210 series of standards. Therefore, the requirements

and tests proposed in this document are intended to be read and applied in accordance with the

appropriate EN ISO 4210 standard.

NOTE The tests described in this document refer in places to clause numbers from the applicable

EN ISO 4210 series.
2 Normative references

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

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

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

EN ISO 4210-2:2015, Cycles - Safety requirements for bicycles - Part 2: Requirements for city and trekking,

young adult, mountain and racing bicycles (ISO 4210-2:2015)

EN ISO 4210-3:2014, Cycles - Safety requirements for bicycles - Part 3: Common test methods

(ISO 4210-3:2014)

EN ISO 4210-4:2014, Cycles - Safety requirements for bicycles - Part 4: Braking test methods

(ISO 4210-4:2014)

EN ISO 4210-6:2015, Cycles - Safety requirements for bicycles - Part 6: Frame and fork test methods

(ISO 4210-6:2015)

EN ISO 4210-7:2014, Cycles - Safety requirements for bicycles - Part 7: Wheels and rims test methods

(ISO 4210-7:2014)
3 Terms and definitions
No terms and definitions are listed in this document.

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

— IEC Electropedia: available at https://www.electropedia.org/
— ISO Online browsing platform: available at https://www.iso.org/obp
4 Frames designed for disc brake
4.1 Background

The forces applied to a bicycle frame by disc brakes are different in magnitude and location to those

applied by rim brakes, so specific tests and requirements are necessary to ensure safety. This section sets

out test procedures and minimum safety requirements for disc brake frames.
---------------------- Page: 6 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
4.2 Test methods
4.2.1 Rear brake mount tests
4.2.1.1 General

When a frame is intended for use with a disc brake and whether supplied as original equipment or as an

accessory, the frame manufacturer shall provide an attachment point on the frame for the caliper.

4.2.2 Static rear brake torque test

Mount the frame in its normal attitude in a fixture and secured either at the rear wheel axis or at the

bottom bracket so that is not restrained in a rotary sense as shown in Figure 1a) or Figure 1b). Fit a

suitable roller to the front axle in order to permit the frame to flex in a fore/aft sense under the test forces.

A dummy fork can be fitted in place of the front fork.

Install a stiff, vertical link with an arm length R according to the maximum outer radius of the tyre

intended for use with the frame or, if this value is not specified by the manufacturer, according to the

maximum wheel diameter as given in Table 2. Further install a rigidly mounted brake disc of appropriate

diameter at the rear dropouts by means of an axle being free to swivel about the axis of the axle but

providing rigidity in a lateral plane.

The brake torque shall be introduced into the brake mount via the link arm in the same way as the actual

caliper would do, i.e.:
a) the link arm can rotate freely on the rear axle;

b) the minimum brake rotor diameter specified by the manufacturer is simulated appropriately; and

c) the link arm is supported by the brake mounts so that only the tangential force, acting on the effective

rotor radius in actual use, is introduced into a suitable brake caliper dummy.

Under no circumstances a rigid connection is to be created between link arm and brake caliper mount, as

shown in Figure 1 c).

Apply a rearward force of 700 N to the link arm against the direction of travel. Maintain this force for 1

min, then reduce the force to 0 and apply a force of 300 N in direction of travel, again maintain this force

for 1 min and release the force.
4.2.3 Rear brake mount fatigue test

Mount the frame in its normal attitude in a fixture in the same manner as for the static rear brake torque

test as shown in Figure 1a) or Figure 1b).

Apply cycles of dynamic, horizontal forces of F in a rearward direction and F in a forward direction to

1 2
the link arm for 20 000 test cycles as shown in Table 1 and Figure 1.
Table 1 — Forces at rear disc brake
Forces in Newton
City and trekking
Bicycle type Young adult bicycle Mountain bicycle Racing bicycle
bicycle
Rearward force, F
500 300 500 400
Forward force, F
50 50 200 50
---------------------- Page: 7 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
Table 2 — Fixture length
Dimensions in millimetres
Wheel diameter 20” 24” 26” 650b 29” or 700c
Arm length, R
254 305 330 349 368
a) fixing the frame to the rear wheel axis
c) applying of the test force
b) fixing the frame to the bottom bracket via the link arm
Key
1 rigid, pivoted mounting
2 free-running guided roller or similar movable bearing
3 locked suspension unit or solid link for pivoted chain stays
4 locking device on brake mount / caliper dummy

5 test adapter for force attachment, free to rotate around the axis of rotation of the rear wheel

6 rotational degree of freedom

R wheel radius according to the maximum outer radius of the tire or according to Table 2

R disc brake mean radius
Figure 1 — Frames for disc-brakes — Rear brake mount fatigue test
---------------------- Page: 8 ----------------------
SIST-TP CEN/TR 17653:2021
CEN/TR 17653:2021 (E)
5 Fork made of composite materials designed for disc brakes
5.1 General

This test shall only apply to forks that contain composite structure at the disc brake caliper mount.

With the development of road (racing) bicycles that utilize new disc brake technology for stopping (either

hydraulic or cable actuated), it is important to understand the result of thermal impact on composites.

This type of thermal loading or thermal input to the brake caliper, brake mount or fork drop out could

possibly cause delamination or dis-bonding. While most scenarios will never see this type of heat

application, it is possible for this happen. It is necessary for safety standards to address this issue.

Requirements (addition to EN ISO 4210 series).

When tested by the method described in 5.2, there shall be no fracture or visible cracks in any part of the

fork and, in the case of suspension forks, there shall be no separation of any parts.

5.2 Test methods

When a fork is intended for use with a hub or disc brake and whether supplied as original equipment or

as an accessory, the fork manufacturer shall provide an attachment point on the fork blade for the torque

arm or caliper.

Where more than one mounting point is provided for a disc brake, the following shall apply:

a) where a complete bicycle is supplied, the test adaptor shall be secured to the mounting point used

on the bicycle. If a bracket is supplied, it shall be used to perform the test;

b) where a fork is supplied as an accessory with more than one mounting point, separate tests shall be

conducted on each of the mounting points on separate forks. The smallest rotor size permitted by the

manufacturer shall be the rotor size used as a test dimension when conducting the test. The rotor

clamp point (size dependent) should be consistent with the test fixture.

Mount the fork in a fixture representative of the head tube according to EN ISO 4210-6:2015, Annex B

and gripped in the normal head-bearings to fit an axle to the fork, and mount on the axle a pivoted,

straight adaptor as shown in Figure 2 to provide a torque arm of L in length (Table 3). The brake

mounting point shall also act as a heat sink capable of applying a co
...

SLOVENSKI STANDARD
kSIST-TP FprCEN/TR 17653:2021
01-marec-2021

Kolesa - Sestavni deli in sklopi za kolesa - Inovativne zahteve in preskusne metode

Cycles - Components and assemblies used in bicycles - Innovative requirements and

test methods

Fahrräder - Verbundwerkstoffe für Fahrräder - Neue Spezifische Prüfverfahren für aus

Verbundwerkstoffe hergestellte Komponenten
Ta slovenski standard je istoveten z: FprCEN/TR 17653
ICS:
43.150 Kolesa Cycles
kSIST-TP FprCEN/TR 17653:2021 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
kSIST-TP FprCEN/TR 17653:2021
---------------------- Page: 2 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FINAL DRAFT
TECHNICAL REPORT
FprCEN/TR 17653
RAPPORT TECHNIQUE
TECHNISCHER BERICHT
February 2021
ICS 43.150
English Version
Cycles - Components and assemblies used in bicycles -
Innovative requirements and test methods

This draft Technical Report is submitted to CEN members for Vote. It has been drawn up by the Technical Committee CEN/TC

333.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,

Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,

Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and

United Kingdom.

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.

Warning : This document is not a Technical Report. It is distributed for review and comments. It is subject to change without

notice and shall not be referred to as a Technical Report.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. FprCEN/TR 17653:2021 E

worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
Contents Page

European foreword ....................................................................................................................................................... 3

1 Scope .................................................................................................................................................................... 4

2 Normative references .................................................................................................................................... 4

3 Terms and definitions ................................................................................................................................... 4

4 Frames designed for disc brake ................................................................................................................. 4

4.1 Background ....................................................................................................................................................... 4

4.2 Test methods .................................................................................................................................................... 5

4.2.1 Rear brake mount tests ................................................................................................................................. 5

4.2.2 Static rear brake torque test ....................................................................................................................... 5

4.2.3 Rear brake mount fatigue test .................................................................................................................... 5

5 Fork made of composite materials designed for disc brakes ......................................................... 7

5.1 General ................................................................................................................................................................ 7

5.2 Test methods .................................................................................................................................................... 7

6 Wheel impact test ............................................................................................................................................ 9

6.1 Background ....................................................................................................................................................... 9

6.2 Requirements ................................................................................................................................................... 9

6.3 Test methods ................................................................................................................................................. 10

7 Front mudguard ............................................................................................................................................ 12

7.1 Background .................................................................................................................................................... 12

7.2 Requirements ................................................................................................................................................ 12

---------------------- Page: 4 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
European foreword

This document (FprCEN/TR 17653:2021) has been prepared by Technical Committee CEN/TC 333

“Cycles”, the secretariat of which is held by UNI.
This document is currently submitted to the Vote on TR.
---------------------- Page: 5 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
1 Scope

The purpose of this document is to provide innovative requirements and test methods applicable to any

components and assemblies of any category of bicycles (city, trekking, MTB, young adult and racing). Its

aim is to provide technical solutions that reduce the risk of component failure and rider injury during the

specified use of such bicycles.

This document makes reference to current “state of the art” standards in the field of bicycles, agreed at

CEN level through the publication of the EN ISO 4210 series of standards. Therefore, the requirements

and tests proposed in this document are intended to be read and applied in accordance with the

appropriate EN ISO 4210 standard.

NOTE The tests described in this document refer in places to clause numbers from the applicable

EN ISO 4210 series.
2 Normative references

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

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

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

EN ISO 4210-2:2015, Cycles - Safety requirements for bicycles - Part 2: Requirements for city and trekking,

young adult, mountain and racing bicycles (ISO 4210-2:2015)

EN ISO 4210-3:2014, Cycles - Safety requirements for bicycles - Part 3: Common test methods

(ISO 4210-3:2014)

EN ISO 4210-4:2014, Cycles - Safety requirements for bicycles - Part 4: Braking test methods

(ISO 4210-4:2014)

EN ISO 4210-6:2015, Cycles - Safety requirements for bicycles - Part 6: Frame and fork test methods

(ISO 4210-6:2015)

EN ISO 4210-7:2014, Cycles - Safety requirements for bicycles - Part 7: Wheels and rims test methods

(ISO 4210-7:2014)
3 Terms and definitions
No terms and definitions are listed in this document.

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

— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at https://www.iso.org/obp
4 Frames designed for disc brake
4.1 Background

The forces applied to a bicycle frame by disc brakes are different in magnitude and location to those

applied by rim brakes, so specific tests and requirements are necessary to ensure safety. This section sets

out test procedures and minimum safety requirements for disc brake frames.
---------------------- Page: 6 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
4.2 Test methods
4.2.1 Rear brake mount tests
4.2.1.1 General

When a frame is intended for use with a disc brake and whether supplied as original equipment or as an

accessory, the frame manufacturer shall provide an attachment point on the frame for the caliper.

4.2.2 Static rear brake torque test

Mount the frame in its normal attitude in a fixture and secured either at the rear wheel axis or at the

bottom bracket so that is not restrained in a rotary sense as shown in Figure 1a) or Figure 1b). Fit a

suitable roller to the front axle in order to permit the frame to flex in a fore/aft sense under the test forces.

A dummy fork can fitted in place of the front fork.

Install a stiff, vertical link with an arm length R according to the maximum outer radius of the tyre

intended for use with the frame or, if this value is not specified by the manufacturer, according to the

maximum wheel diameter as given in Table 2. Further install a rigidly mounted brake disc of appropriate

diameter at the rear dropouts by means of an axle being free to swivel about the axis of the axle but

providing rigidity in a lateral plane.

The brake torque shall be introduced into the brake mount via the link arm in the same way as the actual

caliper would do, i.e.:
a) the link arm can rotate freely on the rear axle,

b) the minimum brake rotor diameter specified by the manufacturer is simulated appropriately and

c) the link arm is supported by the brake mounts so that only the tangential force, acting on the effective

rotor radius in actual use, is introduced into a suitable brake caliper dummy.

Under no circumstances a rigid connection is to be created between link arm and brake caliper mount, as

shown in Figure 1 c).

Apply a rearward force of 700 N to the link arm against the direction of travel. Maintain this force for 1

min, then reduce the force to 0 and apply a force of 300 N in direction of travel, again maintain this force

for 1 min and release the force.
4.2.3 Rear brake mount fatigue test

Mount the frame in its normal attitude in a fixture in the same manner as for the static rear brake torque

test as shown in Figure 1a) or Figure 1b).

Apply cycles of dynamic, horizontal forces of F in a rearward direction and F in a forward direction to

1 2
the link arm for 20 000 test cycles as shown in Table 1 and Figure 1.
Table 1 — Forces at rear disc brake
Forces in Newton
City and trekking
Bicycle type Young adult bicycle Mountain bicycle Racing bicycle
bicycle
Rearward force, F
500 300 500 400
Forward force, F
50 50 200 50
---------------------- Page: 7 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
Table 2 — Fixture length
Dimensions in millimetres
Wheel diameter 20” 24” 26” 650b 29” or 700c
Arm length, R
254 305 330 349 368
a) fixing the frame to the rear wheel axis
c) applying of the test force
b) fixing the frame to the bottom bracket via the link arm
Key
1 rigid, pivoted mounting
2 free-running guided roller or similar movable bearing
3 locked suspension unit or solid link for pivoted chain stays
4 locking device on brake mount / caliper dummy

5 test adapter for force attachment, free to rotate around the axis of rotation of the rear wheel

6 rotational degree of freedom

wheel radius according to the maximum outer radius of the tire or according to Table 2

R disc brake mean radius
Figure 1 — Frames for disc-brakes — Rear brake mount fatigue test
---------------------- Page: 8 ----------------------
kSIST-TP FprCEN/TR 17653:2021
FprCEN/TR 17653:2021 (E)
5 Fork made of composite materials designed for disc brakes
5.1 General

This test shall only apply to forks that contain composite structure at the disc brake caliper mount.

With the development of road (racing) bicycles that utilize new disc brake technology for stopping (either

hydraulic or cable actuated) it is important to understand the result of thermal impact on composites.

This type of thermal loading or thermal input to the brake caliper, brake mount or fork drop out could

possibly cause delamination or dis-bonding. While most scenarios will never see this type of heat

application, it is possible for this happen. It is necessary for safety standards to address this issue.

Requirements (addition to EN ISO 4210 series)

When tested by the method described in 5.2, there shall be no fracture or visible cracks in any part of the

fork and, in the case of suspension forks, there shall be no separation of any parts.

5.2 Test methods

When a fork is intended for use with a hub or disc brake and whether supplied as original equipment or

as an accessory, the fork manufacturer shall provide an attachment point on the fork blade for the torque

arm or caliper.

Where more than one mounting point is provided for a disc brake, the following shall apply:

a) where a complete bicycle is supplied, the test adaptor shall be secured to the mounting point used

on the bicycle. If bracket is supplied, it shall be used to perform the test;

b) where a fork is supplied as an accessory with more than one mounting point, separate tests shall be

conducted on each of the mounting points on separate forks. The smallest rotor size permitted by the

manufacturer shall be the rotor size used as a test dimension when conducting the test. The rotor

clamp point (size dependent) should be consistent with the test fixture.

Mount the fork in a fixture representative of the head tube according to EN ISO 4210-6:2015, Annex B

and gripped in the normal head-bearings to fit an axle to the fork, and mount on the axle a pivoted,

straight adaptor as shown in Figure 2 to provide a torque arm of L in length (Table 3). The brake

...

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