ISO 16750-3:2012

INTERNATIONAL ISO
STANDARD 16750-3
Third edition
2012-12-15
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
Reference number
©
ISO 2012
© ISO 2012
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Published in Switzerland
ii © ISO 2012 – All rights reserved

Contents Page
Foreword .iv
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Tests and requirements . 1
4.1 Vibration . 1
4.2 Mechanical shock .27
4.3 Free fall .29
4.4 Surface strength/scratch and abrasion resistance .29
4.5 Gravel bombardment .29
5 Code letters for mechanical loads .29
6 Documentation .30
Annex A (informative) Guideline for the development of test profiles for vibration tests .32
Annex B (informative) Recommended mechanical requirements for equipment depending on the
mounting location .44
Bibliography .46
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.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International
Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies
casting a vote.
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.
ISO 16750-3 was prepared by Technical Committee ISO/TC 22, Road vehicle, Subcommittee SC 3,
Electrical and electronical equipment.
This third edition cancels and replaces the second edition (ISO 16750-3:2007), which has been
technically revised.
ISO 16750 consists of the following parts, under the general title Road vehicles — Environmental conditions
and testing for electrical and electronic equipment:
— Part 1: General
— Part 2: Electrical loads
— Part 3: Mechanical loads
— Part 4: Climatic loads
— Part 5: Chemical loads
iv © ISO 2012 – All rights reserved

INTERNATIONAL STANDARD ISO 16750-3:2012(E)
Road vehicles — Environmental conditions and testing for
electrical and electronic equipment —
Part 3:
Mechanical loads
1 Scope
This part of ISO 16750 applies to electric and electronic systems/components for road vehicles. It
describes the potential environmental stresses and specifies tests and requirements recommended for
the specific mounting location on/in the vehicle.
This part of ISO 16750 describes mechanical loads.
2 Normative references
The following referenced documents are indispensable for the application 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.
ISO 16750-1, Road vehicles — Environmental conditions and testing for electrical and electronic equipment —
Part 1: General
IEC 60068-2, 6, Environmental testing — Part 2-6: Testing, Test Fc: Vibration (Sinusoidal)
IEC 60068-2, 14, Basic environmental testing procedures — Part 2-14: Tests — Test Nb: Change of temperature
IEC 60068-2, 64, Environmental testing — Part 2-64: Test methods — Test Fh — Vibration, broad-band
random (digital control) and guidance
IEC 60068-2, 80, Environmental testing — Part 2-80: Tests — Test Fi: Vibration — Mixed mode testing
IEC 60068-2-31, Environmental testing procedures — Part 2: Tests; Test Ec: Free fall, Clause 5.2
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 16750-1 apply.
4 Tests and requirements
4.1 Vibration
4.1.1 General
The vibration test methods specified consider various levels of vibration severities applicable to on-
board electrical and electronic equipment. It is recommended that the vehicle manufacturer and
supplier choose the test method, the environmental temperature and vibration parameters depending
on the specific mounting location.
Following the expressions in MIL-STD please notice:
When applied properly, the environmental management and engineering processes described in this part
of ISO 16750 can be of enormous value in generating confidence in the environmental worthiness and
overall durability. However, it is important to recognize that there are limitations inherent in laboratory
testing that make it imperative to use proper caution and engineering judgement when extrapolating these
laboratory results to results that may be obtained under actual service conditions. In many cases, real-
world environmental stresses (singularly or in combination) cannot be duplicated practically or reliably in
test laboratories. Therefore, users of this part of ISO 16750 should not assume that a system or component
that passes laboratory tests of this part of ISO 16750 would also pass field/fleet verification trials.
— “The specified values are the best estimation one can get up to the moment when results from
measurements in the car are received – but they do not replace a car measurement!”
The specified values apply to direct mounting in defined mounting locations. Using a bracket for
mounting can result in higher or lower loads. If the device under test (DUT) is used in the vehicle with a
bracket then all vibration and mechanical shock test shall be done with this bracket.
Carry out the vibration with the DUT suitably mounted on a vibration table. The mounting method(s)
used shall be noted in the test report. Carry out the frequency variation by logarithmic sweeping of 0,5
octave/minute for sinusoidal tests and the sinusoidal part of sine on random tests. The scope of the
recommended vibration tests is to avoid malfunctions and breakage mainly due to fatigue in the field.
Testing for wear has special requirements and is not covered in this part of ISO 16750.
Loads outside of the designated test frequency ranges are to be considered separately.
NOTE Deviations from the load on the DUT can result, should vibration testing be carried out according to
this part of ISO 16750 on a heavy and bulky DUT, as mounting rigidity and dynamic reaction on the vibrator table
excitation are different compared to the situation in the vehicle. This deviation can be minimized by applying the
average control method (see Annex A).
Application of the weighted average control method according to IEC 60068-2, 64 is to be agreed upon.
Subject the DUT during the vibration test to the temperature cycle according to IEC 60068-2, 14, with
electric operation according to diagram 1. Alternatively, a test at constant temperature may be agreed on.
Operate the DUT electrically as indicated in Figure 1 at T (short functional test after the DUT completely
min
reached T . This functional test shall be as short as possible ― only long enough to check the proper
min)
performance of the DUT. This minimizes self-heating of the DUT. Additional electrical operation of the
DUT between 210 min and 410 min of the cycle (see Figure 1).
Additional drying of test chamber air is not permitted.
In the vehicle, vibration stress can occur together with extremely low or high temperatures; for this
reason, this interaction between mechanical and temperature stress is simulated in the test, too. A
failure mechanism is, for example, a plastic part of a system/component, which mellows due to the high
temperature and cannot withstand the acceleration under this condition.
2 © ISO 2012 – All rights reserved

Key
Y temperature [°C]
X time [min]
a
Operating mode 3.2 according to ISO 16750-1.
b
Operating mode 2.1 according to ISO 16750-1.
c
One cycle.
Figure 1 — Temperature profile for the vibration test
Table 1 — Temperature versus time for the vibration test
Time Temperature
min °C
0 20
60 -40
150 -40
210 20
a
300 T
max
a
410 T
max
480 20
a
See ISO 16750-4.
4.1.2 Tests
4.1.2.1 Test I — Passenger car, engine
4.1.2.1.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
The vibrations of a piston engine can be split up into two kinds: Sinusoidal vibration which results from the
unbalanced mass forces in the cylinders and random noise due to all other vibration-schemes of an engine,
e.g. closing of valves. In the lowest frequency range from 10 Hz to 100 Hz the influence of rough-road
conditions is taken into account. The main failure to be identified by this test is breakage due to fatigue.
NOTE 1 Road profile usually has negligible impact on engine-mounted components. Shock inputs are effectively
isolated by suspension, and engine-mounting systems.
The test profiles specified in the following clauses apply to loads generated by (four stroke)
reciprocating engines.
NOTE 2 If the DUT is to be tested for a specific resonance effect, then a resonance dwell test according to 8.3.2
of IEC 60068-2, 6:2007 can also be applied.
4.1.2.1.2 Test
4.1.2.1.2.1 General
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
NOTE The test duration is based on A.4. The temperature in the chamber is above room temperature (RT) at
the end of the test (2 3/4 temperature cycles).
4.1.2.1.2.2 Sinusoidal vibration
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 22 h for each plane of the DUT.
Use curve 1 in Table 2/Figure 2 for DUT intended for mounting on engines with 5 cylinders or fewer.
Use curve 2 in Table 2/Figure 2 for DUT test intended for mounting on engines with 6 cylinders or more.
Both curves may be combined to cover all engine types in one test.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
curve 1 (≤5 cylinders)
curve 2 (>5 cylinders)
Figure 2 — Vibration severity curves
4 © ISO 2012 – All rights reserved

Table 2 — Values for max. acceleration versus frequency
Curve 1 (see Figure 2)
Frequency Amplitude of acceleration
Hz m/s
100 100
200 200
240 200
270 100
440 100
Curve 2 (see Figure 2)
Frequency Amplitude of acceleration
Hz m/s
100 100
150 150
440 150
Combination
Frequency Amplitude of acceleration
Hz m/s
100 100
150 150
200 200
240 200
255 150
440 150
4.1.2.1.2.3 Random vibration
Perform the test according to IEC 60068-2, 64. Use a test duration of 22 h for each plane of the DUT.
The r.m.s. acceleration value shall be 181 m/s .
The PSD versus frequency are referred to in Figure 3 and Table 3
NOTE The Power Spectral Density (PSD) values (random vibration) are reduced in the frequency range of the
sinusoidal vibration test.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 3 — PSD of acceleration versus frequency
Table 3 — Values for frequency and PSD
Frequency PSD
2 2
Hz (m/s ) /Hz
10 10
100 10
300 0,51
500 20
2 000 20
4.1.2.1.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.2 Test II — Passenger car, gearbox
4.1.2.2.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
The vibrations of a gearbox can be split up into two kinds which result partly from sinusoidal vibration
from unbalanced mass forces of the engine (e.g. dominating orders) in the frequency range from 100 Hz
to 440 Hz and vibration from the friction of the gear wheels and other schemes, which are tested in the
random part. In the lowest frequency range from 10 Hz to 100 Hz the influence of rough-road conditions
is taken into account. The main failure to be identified by this test is breakage due to fatigue.
The test profiles specified in the following subclauses apply to loads generated by gearbox vibrations.
Changing the gears can create additional mechanical shock and shall be considered separately.
6 © ISO 2012 – All rights reserved

4.1.2.2.2 Test
4.1.2.2.2.1 General
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
NOTE The test duration is based on A.4. The temperature in the chamber is above RT at the end of the test
(2 3/4 temperature cycles).
4.1.2.2.2.2 Sinusoidal vibration
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 22 h for each plane of the DUT.
The amplitude versus frequency are referred to in Figure 4 and Table 4.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 4 — Acceleration versus frequency
Table 4 — Values for frequency and acceleration
Frequency PSD
Hz m/s
100 30
200 60
440 60
4.1.2.2.2.3 Random vibration
Perform the test according to IEC 60068-2, 64. Use a test duration of 22 h for each plane of the DUT.
The r.m.s. acceleration value shall be 96,6 m/s .
NOTE The PSD values (random vibration) are reduced in the frequency range of the sinusoidal vibration test.
The PSD versus frequency are referred to in Figure 5 and Table 5.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 5 — PSD of acceleration versus frequency
Table 5 — Values for frequency and PSD
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 10
100 10
300 0,51
500 5
2 000 5
4.1.2.2.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.3 Test III — Passenger car, flexible plenum chamber
4.1.2.3.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
This test is applicable to equipment to be mounted on flexible plenum chamber and/or connected to a
source of air pulsations (e.g. intake manifold could be a source of air pulsations).
The vibrations are sinusoidal and mainly induced by the pulsation of the intake air.
NOTE This means even in case the DUT is mounted in another area (e.g. car body), connecting the DUT with
a tube to the intake manifold leads to vibration load resulting out of air pulsation.
The main failure to be identified by this test is breakage due to fatigue.
8 © ISO 2012 – All rights reserved

4.1.2.3.2 Test
Perform the test according to IEC 60068-2, 6 sinusoidal vibration, but a sweep rate of ≤ 0,5 octave/minute
shall be used. Use a test duration of 22 h for each plane of the DUT.
NOTE The test duration is based on A.4. The temperature in the chamber is above RT at the end of the test
(2 3/4 temperature cycles).
The amplitude versus frequency are referred to in Figure 6 and Table 6.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 6 — Max. acceleration versus frequency
Table 6 — Values for acceleration and frequency
Frequency Amplitude of acceleration
Hz (m/s )
100 90
200 180
325 180
500 80
1 500 80
4.1.2.3.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes
4.1.2.4 Test IV — Passenger car, sprung masses (vehicle body)
4.1.2.4.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration of the body is random vibration induced by rough-road driving. The main failure to be
identified by this test is breakage due to fatigue.
4.1.2.4.2 Test
Perform the test according to IEC 60068-2, 64 random vibration. Use a test duration of 8 h for each
plane of the DUT.
The r.m.s. acceleration value shall be 27,1 m/s .
The PSD versus frequency are referred to in Figure 7 and Table 7.
NOTE The test duration is based on A.5.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 7 — PSD of acceleration versus frequency
Table 7 — Values for PSD and frequency
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 30
400 0,2
1 000 0,2
10 © ISO 2012 – All rights reserved

4.1.2.4.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.5 Test V — Passenger car, unsprung masses (wheel, wheel suspension)
4.1.2.5.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration of unsprung masses is random vibration induced by rough-road driving. The main failure to
be identified by this test is breakage due to fatigue.
Loads with frequencies lower than 20 Hz are not covered by the test profile specified here. In practice
high amplitudes can occur below 20 Hz; therefore, loads acting on the DUT in this frequency range shall
be considered separately.
4.1.2.5.2 Test
Perform the test according to IEC 60068-2, 64 random vibration. Use a test duration of 8 h for each
plane of the DUT.
The r.m.s. acceleration is 107,3 m/s .
The PSD versus frequency are referred to in Figure 8 and Table 8.
NOTE The test duration is based on A.5.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 8 — PSD of acceleration versus frequency
Table 8 — Values for PSD and frequency
Frequency PSD
2 2
Hz [(m/s ) /Hz]
20 200
40 200
300 0,5
800 0,5
1 000 3
2 000 3
4.1.2.5.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.6 Test VI — Commercial vehicle, engine, gearbox
4.1.2.6.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
The vibrations of a piston-engine can be split up into two kinds: sinusoidal vibration which results
from unbalanced mass forces and random noise due to all other vibration sources of an engine, e.g.
closing of valves.
Because the gearbox is rigidly attached to the engine, this test can also be used for systems/components
mounted at the gearbox. But there is no sufficient number of measurements on gearbox-mounted
systems/components performed up to now.
The main failure to be identified by this test is breakage due to fatigue.
If the DUT has natural frequencies below 30 Hz, an additional test is to be carried out with a duration of
32 h in all critical planes of the DUT.
4.1.2.6.2 Test
4.1.2.6.2.1 General
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
NOTE The temperature in the chamber is above RT at the end of the test (11 3/4 cycles).
4.1.2.6.2.2 Sinusoidal vibration
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 94 h for each plane of the DUT (equivalent to approx. 20 h per octave). This is equivalent to
10 cycles in resonance in case of resonance bandwidth of 100 Hz or more. See Table A.2.
The amplitude versus frequency are referred to in Figure 9 and Table 9.
12 © ISO 2012 – All rights reserved

Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 9 — Max. acceleration versus frequency
Table 9 — Values for max. acceleration and frequency
Frequency Amplitude of displacement Amplitude of acceleration
Hz (mm) (m/s )
20 0,72 (11,4)
65 0,72 120
260 120
260 90
350 90
350 60
520 60
4.1.2.6.2.3 Random vibration
Perform the test according to IEC 60068-2, 64.
Test duration:
— 94 h for each plane of the DUT (standard) (see Figure 10 and Table 10),
— 32 h additionally for each critical plane of the DUT (for natural frequencies below 30 Hz) (see Table 11).
NOTE The PSD values (random vibration) are reduced in the frequency range of the sinusoidal vibration test.
The PSD versus frequency are referred to in Figure 10 and Tables 10 and 11.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
standard random test profile
additional profile in case of f < 30 Hz
n
Figure 10 — PSD of acceleration versus frequency
Table 10 — Values for PSD and frequency
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 14
20 28
30 28
180 0,75
300 0,75
600 20
2 000 20
r.m.s. acceleration value = 177 m/s
14 © ISO 2012 – All rights reserved

Table 11 — Values for PSD and frequency, additional test in case of natural frequencies f of
n
DUT below 30 Hz
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 50
30 30
45 0,1
r.m.s. acceleration value = 28,6 m/s
4.1.2.6.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.7 Test VII — Commercial vehicle, sprung masses
4.1.2.7.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration on sprung masses is random vibration induced by rough-road driving. The main failure to be
identified by this test is breakage due to fatigue.
4.1.2.7.2 Test
Perform the test according to IEC 60068-2, 64, random vibration. Use a test duration of 32 h for each
plane of the DUT.
The PSD versus frequency are referred to in Figure 11 and Tables 12 and 13.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
standard random test profile
additional profile in case of f < 30 Hz
n
Figure 11 — PSD of acceleration versus frequency
Table 12 — Values for PSD and frequency
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 18
20 36
30 36
180 1
2 000 1
r.m.s. acceleration value = 57,9 m/s
Table 13 — Values for PSD and frequency, additional test in case of natural frequencies f of
n
DUT below 30 Hz
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 50
20 36
30 36
45 16
r.m.s. acceleration value = 33,7 m/s
4.1.2.7.3 Requirement
Breakage shall not occur.
16 © ISO 2012 – All rights reserved

Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.8 Test VIII — Commercial vehicle, decoupled cab
4.1.2.8.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration on a decoupled commercial vehicle cab is random vibration induced by rough-road driving.
The main failure to be identified by this test is breakage due to fatigue.
4.1.2.8.2 Test
Perform the test according to IEC 60068-2, 64, random vibration.
Test duration: 32 h for each plane of the DUT.
The PSD versus frequency are referred to in Figure 12 and Table 14.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
vertical
lateral
longitudinal
Figure 12 — PSD of acceleration versus frequency
Table 14 — Values for PSD and frequency
2 2
Frequency PSD [(m/s ) /Hz]
[Hz]
vertical longitudinal lateral
10 20 3 10
13 - - 10
19 - 3 -
20 20 - -
50 - 0,1 0,1
100 0,1 - -
500 0,1 0,1 0,1
2 000 0,01 0,01 0,01
2 2 2
r.m.s. acceleration value 21,3 m/s 11,8 m/s 13,1 m/s
4.1.2.8.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.9 Test IX — Commercial vehicle, unsprung masses
4.1.2.9.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration on unsprung masses is vibration induced by rough-road driving. The main failure to be
identified by this test is breakage due to fatigue.
4.1.2.9.2 Test
Perform the random vibration test VII as in 4.1.2.7.2 and in addition the sinusoidal vibration test
described below.
Carry out the sinusoidal vibration test at RT.
The sinusoidal vibration test according to Table 15 describes the maximum amplitudes of acceleration
on wheels and wheel suspension and the respective frequencies. If natural frequencies of the DUT below
40 Hz can be ruled out, the test can be carried out with a test frequency of 35 Hz (see Figure 16) so that
it can be performed on an electro-mechanical test stand.
18 © ISO 2012 – All rights reserved

Table 15 — Values for max. acceleration and frequency in case of lowest natural frequency of
a DUT < 40 Hz
Plane as mounted Frequency Amplitude of acceleration Duration No. of cycles
in vehicle [Hz] [m/s ] [min] (approx.)
longitudinal, 8 to 16 150 4 2 800
lateral
8 to 16 120 10 7 000
8 to 32 100 20 21 000
vertical 8 to 16 300 4 2 800
8 to 16 250 10 7 000
8 to 32 200 20 21 000
Table 16 — Values for max. acceleration and frequency in case of lowest natural frequency of
a DUT ≥ 40 Hz
Plane as mounted in vehicle Frequency Amplitude of acceleration No. of cycles
[Hz] [m/s ] (approx.)
longitudinal, lateral 35 150 2 800
35 120 7 000
35 100 21 000
vertical 35 300 2 800
35 250 7 000
35 200 21 000
4.1.2.9.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.10 Test X — Passenger car, fuel rail (gasoline engine with GDI-system)
4.1.2.10.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration load on rail-mounted components is mainly influenced by rail resonances. Depending on design
and mounting the rail resonance frequency will occur between approximately 700 Hz and 2000 Hz. The
main failure to be identified by this test is breakage due to fatigue.
4.1.2.10.2 Test
4.1.2.10.2.1 General
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
4.1.2.10.2.2 Sinusoidal vibration
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 40 h for each plane of the DUT. The amplitude versus frequency are referred to in Figure 13
and Table 17.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 13 — Acceleration versus frequency
Table 17 — Values for frequency and acceleration
Frequency Amplitude of acceleration
Hz m/s
100 50
400 50
500 120
850 230
1 500 230
2 000 150
4.1.2.10.2.3 Random vibration
Perform the test according to IEC 60068-2, 64. Use a test duration of 40 h for each plane of the DUT.
The r.m.s. acceleration value shall be 331 m/s .
The PSD versus frequency are referred to in Figure 14 and Table 18.
20 © ISO 2012 – All rights reserved

Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 14 — PSD of acceleration versus frequency
Table 18 — Values for frequency and PSD
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 10
100 10
900 75
1 750 75
2 000 18
4.1.2.10.2.4 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.11 Test XI — Passenger car, solid intake manifold
4.1.2.11.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration on intake manifold components is influenced by resonances of the manifold and air pulsation.
Out of this there is a difference between the conditions on engine and manifold.
This test is applicable for manifolds made of plastics and for those made of metal.
The main failure to be identified by this test is breakage due to fatigue.
4.1.2.11.2 Test
4.1.2.11.2.1 General
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
NOTE The test duration is based on A.4. The temperature in the chamber is above RT at the end of the test
(2 3/4 temperature cycles).
4.1.2.11.2.2 Sinusoidal vibration
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 22 h for each plane of the DUT.
The amplitude versus frequency are referred to in Figure 15 and Table 19.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 15 — Acceleration versus frequency
Table 19 — Values for frequency and acceleration
Frequency Amplitude of acceleration
Hz (m/s )
100 50
150 100
200 150
240 150
300 75
440 75
4.1.2.11.2.3 Random vibration
Perform the test according to IEC 60068-2, 64. Use a test duration of 22 h for each plane of the DUT.
22 © ISO 2012 – All rights reserved

The r.m.s. acceleration value shall be 184,5 m/s .
NOTE The PSD values (random vibration) are reduced in the frequency range of the sinusoidal vibration test.
The PSD versus frequency are referred to in Figure 16 and Table 20.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 16 — PSD of acceleration versus frequency
Table 20 — Values for frequency and PSD
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 10
100 10
200 2
500 20
2 000 20
4.1.2.11.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
4.1.2.12 Test XII — Passenger car, exhaust pipe
4.1.2.12.1 Purpose
This test checks the DUT for malfunctions and breakage caused by vibration.
Vibration on exhaust pipe mounted components is influenced by resonances of the pipe and exhaust
pulsation. Out of this there may be a difference between the conditions on engine and exhaust pipe,
depending, for example, on the distance between the engine and application area.
The main failure to be identified by this test is breakage due to fatigue.
There are three tests to be defined:
XIIa valid for sensors with natural frequencies > 1 000 Hz;
XIIb valid for modules, mounted before the decoupling element;
XIIc valid for modules, mounted behind the decoupling element.
4.1.2.12.2 Test conditions
Test conditions XIIa: valid for sensors with natural frequencies > 1000 Hz
Perform the test according to IEC 60068-2, 6, but using a sweep rate of ≤ 0,5 octave/minute. Use a test
duration of 50 h for each plane of the DUT. This is equivalent to 5 x 10 cycles in resonance in case of
resonance bandwidth of 100 Hz or more. See Table A.2.
The amplitude versus frequency are referred to in Figure 17 and Table 21.
Ambient temperature: as measured in the car, e.g. 600 °C on the mounting position.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 17 — Acceleration versus frequency
Table 21 — Frequency and amplitude
Frequency Amplitude
Hz
50 to 160 0,3 mm
160 to 2 000 300 m/s
24 © ISO 2012 – All rights reserved

Test conditions for XIIb: valid for modules, mounted before the decoupling element
The DUT has to be tested following to the conditions as defined for engine mounted components.
The temperature in the chamber shall be defined between customer and supplier.
Test conditions for XIIc: valid for modules, mounted behind the decoupling element
This test checks the DUT for malfunctions and breakage caused by vibration.
Test – General, for XIIc
It is required to perform this test as a mixed mode vibration test according to IEC 60068-2, 80.
The temperature in the chamber shall be defined between customer and supplier.
Sinusoidal vibration for XIIc
Perform the test according to IEC 60068-2, 6, but a sweep rate of ≤ 0,5 octave/minute shall be used. Use
a test duration of 40 h for each plane of the DUT.
The amplitude versus frequency are referred to Figure 18 and Table 22.
Key
Y amplitude of acceleration [m/s ]
X frequency [Hz]
Figure 18 — Acceleration versus frequency
Table 22 — Values for frequency and acceleration
Frequency Amplitude of acceleration
Hz (m/s )
125 to 250 60
250 to 500 40
Random vibration for XIIc
Perform the test according to IEC 60068-2, 64. Use a test duration of 40 h for each plane of the DUT.
The r.m.s. acceleration value shall be 67,4 m/s .
The PSD versus frequency are referred to Figure 19 and Table 23.
Key
2 2
Y PSD [(m/s ) /Hz]
X frequency [Hz]
Figure 19 — PSD of acceleration versus frequency
Table 23 — Values for frequency and PSD
Frequency PSD
2 2
Hz [(m/s ) /Hz]
10 14
20 28
30 28
180 0,75
300 0,75
500 2
2 000 2
4.1.2.12.3 Requirement
Breakage shall not occur.
Functional status A (see ISO 16750-1) is required during operating mode 3.2 as defined in ISO 16750-1,
and functional status C during periods with other operating modes.
26 © ISO 2012 – All rights reserved

4.2 Mechanical shock
4.2.1 Test for devices in or on doors and flaps
4.2.1.1 Purpose
This test checks the DUT for malfunctions and breakage caused by shock of door slamming.
The load occurs on closures when slammed shut. Failure mode is mechanical damage (e.g. a detached capacitor
inside the housing of electronic control module due to the high accelerations caused by door slamming).
4.2.1.2 Test
Choose one of the profiles indicated in Table 24 and perform the test according to IEC 60068-2, 27:
— operating mode of the DUT: 1.2 (see ISO 16750-1);
— shock form (pulse shapes): half-sinusoidal.
The DUT shall be fixed on the shaker in a direction to generate the effect of acceleration in the same
direction as it occurs in vehicle use.
Table 24 — Number of shocks
Shock profile 1 Shock profile 2
2 2
500 m/s ; 11 ms 300 m/s ; 6 ms
Driver’s door, cargo door 13 000 100 000
Passenger’s doors 6 000 50 000
Trunk lid, tailgate 2 400 30 000
Engine hood 720 3 000
4.2.1.3 Requirement
Breakage shall not occur. Functional status shall be class C as defined in ISO 16750-1.
4.2.2 Test for devices on rigid points on the body and on the frame
4.2.2.1 Purpose
This test checks the DUT for malfunctions and breakage caused by shock to body and frame.
The load occurs when driving over a curb stone at high speed, etc. Failure mode is mechanical damage
(e.g. a detached capacitor inside the housing of an electronic control module due to the occurring high
accelerations).
4.2.2.2 Test
Perform the test according to IEC 60068-2, 27:
operating mode of the DUT: 3.2 (see ISO 16750-1);
pulse shape: half-sinusoidal;
acceleration: 500 m/s ;
duration: 6 ms;
— number of shocks: 10 per test direction.
Acceleration due to the shock in the test shall be applied in the same direction in which the acceleration
of the shock occurs in the vehicle. If the direction of the effect is not known, the DUT shall be tested in
all six spatial directions.
4.2.2.3 Requirement
Breakage shall not occur. Functional status shall be class A as defined in ISO 16750-1.
4.2.3 Test for devices in or on the gearbox
4.2.3.1 Purpose
This test checks the DUT for malfunctions and breakage caused by shock of gear shifting.
This test is applicable to DUT intended for mounting in or on the gearbox.
The loads occur during pneumatic powered gear-shifting operations. Failure mode is mechanical
damage (e.g. a detached capacitor inside the housing of an electronic control module due to the high
accelerations caused by pneumatically powered gear-shifting operations).
4.2.3.2 Test
Perform the test according to IEC 60068-2, 27:
— operating mode of the DUT: 3.2 (see ISO 16750-1);
— pulse shape: half-sinusoidal;
— typical max. acceleration:
2 2
(in single cases measured up to 50 000 m/s ),
— for commercial vehicles: 3 000 m/s
— for passenger cars: to be agreed between customer and supplier;
— typical duration: < 1 ms;
temperature: to be agreed between customer and supplier;
number of shocks: to be agreed between customer and supplier.
The aforementioned values for commercial vehicles occur primarily during pneumatically supported
gear-shifting operations (150 000 gear-shifting operations are typical if a range-change system is fitted).
The actual shock stresses depend both on the installation position of the gearbox and also on the design
features of the gearbox and shall in individual cases be ascertained by means of suitable measurements
(recommended sampling frequency: at least 25 kHz). A test shall be arranged between the manufacturer
and the user.
The acceleration due to the shock in the test shall be applied in the same direction in which the
acceleration of the shock occurs in the vehicle. If the direction of the effect is not known, the DUT shall
be tested in all six spatial directions.
4.2.3.3 Requirement
Breakage shall not occur. Functional status shall be class A as defined in ISO 16750-1.
28 © ISO 2012 – All rights reserved

4.3 Free fall
4.3.1 Purpose
This test checks the DUT for malfunctions and breakage caused by free fall.
A system/component may drop down to the floor during handling (e.g. at the manufacturing line of
the car manufacturer). If a system/component is visibly damaged after a fall, it will be replaced. But if
it is not visibly damaged, it will be installed in the car and then it shall work correctly. Failure mode is
mechanical damage (e.g. a detached capacitor inside the housing of an electronic control module due to
the high accelerations when the DUT hits the ground).
4.3.2 Test
Parts that obviously will be damaged by the fall shall not be checked (e.g. headlights). Parts that may
withstand falling without visible damage shall be checked as follows:
Perform the test sequence according to IEC 60068-2, 31 using the following test parameters:
number of DUT: 3;
falls per DUT: 2;
drop height: 1 m free fall or the height of handling according to agreement;
impact surface: concrete ground or steel plate;
orientation of the DUT: 1st fall of each DUT at a different dimensional axis, 2nd fall with
the given DUT at the same dimensional axis but on the opposite
side of the housing;
operating mode of the DUT: 1.1 (see ISO 16750-1;)
temperature: has to be agreed between customer and supplier.
The DUT shall be visually examined after the falls.
4.3.3 Requirement
Hidden damage is not permitted. Minor damage of the housing is permitted as long as this does not
affect the performance of the DUT. Proper performance shall be proven following the test.
Functional status shall be class C as defined in ISO 16750-1.
4.4 Surface strength/scratch and abrasion resistance
Tests and requirements shall be agreed upon between manufacturer and customer (e.g. marking and
labelling on control elements and keys shall remain visible).
4.5 Gravel bombardment
This test checks the resistance against gravel bombardment (in exposed mounting locations, e.g. front end).
5 Code letters for mechanical loads
See Table 25.
6 Documentation
For documentation the designations outlined in ISO 16750-1 shall be used.
30 © ISO 2012 – All rights reserved

Table 25 — Coding in relation to tests and requirem
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