PERFORMANCE

ROOF BAR/ANCHOR STRENGTH TEST STANDARD

Off-vehicle static test 7-N4160
Page: 1 of 15
normazione
Date: 10th December 2004

SUPERVISING DEPT.: E.&D. – P.T.&S. - Arese

PCA
MANAGING DEPT.: E.&D. – P.T.&S. - Sperimentazione Banco

Code
--
Ch.
1

6
APPLICATION CRITERIA

To verify static strength of both roof bar anchor and roof bar.
For vehicles with roof bar attached to trunk lid no static test is envisaged. On-vehicle dynamic test

Issue
shall apply.
Static test: Off-vehicle simulated on-vehicle vertical/longitudinal/transverse loading of roof bar.

Change Date Description

– June 88 Issue 1 – New.

– Nov. 94 Issue 2 – Edited as per 7-G0020.

– May 96 Issue 3 – Revised and updated.

– Jan. 01 Issue 4 – Test schedule revised. Supervisor changed. (AN)

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE THE ONLY
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES
– Oct. 03 Issue 5 – Supervisor changed (was Amort). (AN)

– Dec. 04 Issue 6 – Units of measure revised. Editorial changes. (AN)

VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.
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AS UPDATE STATUS OF PRINTOUTS CANNOT BE MONITORED, CHECK THE WEB SITE FOR THE LATEST EDITION OF DOCUMENT

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REFERENCES

7-G0030 Significance of items under test (PGE)

Folder F17 Tightening torques major components

TEST EQUIPMENT

• Prototype body complete with moving parts, after temperature cycling as in production after
spraying, with windshield and backlight installed or adhesive bonded (as applicable)
• Static test setup
• Rigid mock-up of front and rear roof bar anchoring supports 600 x 1000 x 50 mm. Point of load
application at center and on upper face.
• Clock gauges/transducers with power supply
• Gauge/transducer support equipment
• Load applicator, lateral-longitudinal-transverse
• Load cell/dynamometer, 500 daN (± 5 daN)
• Set of roof bars

Note: Equivalent equipment may be substituted but must be equal or superior in performance.
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DESCRIPTION OF ITEM UNDER TEST

Vehicle type

Chassis No.

Bar anchor type

Bar drawing number

Roof bar supplier

Roof bar description

Test purpose
Preliminary [ ] Final [ ] [ ]
Certification
design design
Development stage
Reliability tests [ ] Prod. impr. [ ]

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SIGNIFICANCE OF COMPONENTS UNDER TEST

COMPONENT WEIGHT AND CHARACTERISTICS FOR EVALUATING TEST SIGNIFICANCE

Type of % Weight Component affecting test Significant Min. build
component Significance (B) significance characteristics level
% (A)
Active 0.45 Roof area for rack Solution, material, C
anchorage thicknesses, spot
welds as per dwg.
Active 0.45 Roof bar Supplier quality C
control Profile and
dimensions
Material as per
drawing
Active 0.1 Bodyshell Sprayed bodyshell C
structurally sound,
Material,
Thicknesses, Spot
welds in roof area
as per dwg.

Significance of item under test (%) = Σ ( A x B ) =

Note: For each component, evaluate % significance for the three distinct levels indicated in
Standard 7-G0030, recording values in column A.
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

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PRELIMINARY OPERATIONS

6.1
Secure body/vehicle to static test setup (moving parts shut). Test Op. [ ]
6.2
Install roof bar onto anchors of body/vehicle adhering to instructions supplied by Test Op. [ ]
the manufacturer and using the tools provided with the roof bar.
6.3
If the bars can be adjusted in height, they should be installed at maximum Test Op. [ ]
height.
6.4
Tighten fasteners bar to roof and bar to bar at minimum of tolerance. Test Op. [ ]
6.5
Enter roof bar installability data in “Data processing” Table A. Engineer [ ]
Test Op. [ ]
6.6
Install rigid mock-up (1000 x 600 x 50 mm) for positive connection of front and Test Op. [ ]
rear roof rack bars.
6.7
Attach load applicator to test setup (for vertical/longitudinal/transverse loading). Test Op. [ ]
6.8
Settle the assembly applying 30 daN load vertically/longitudinally and Test Op. [ ]
transversally.
6.9
Monitor fastener tightening torques and enter readings in Data processing Engineer [ ]
Table A. Test Op. [ ]

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6.10
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES
Position clock gauge/transducer at point of load application and in the same Test Op. [ ]
direction (reference for test point is the body side member).
6.11
VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

Place clock gauge/transducer on right front and rear roof bar brackets in area of Test Op. [ ]
retention to roof and in the direction of load in question (reference for this test
point is the body side member).
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TEST PROCEDURE

7.1
Static test – vertical load

7.1.1
Apply 240 daN + 0.5 upward vertical load on centerline of mockup front roof bar, Engineer [ ]
this being the max. permissible (design) load. Test Op. [ ]
Note: Load applied gradually and progressively over a period of between 60 and 65 seconds.
7.1.2
Apply load for 10 min. Test Op. [ ]
7.1.3
Monitor total displacement at load application point and enter reading in Engineer [ ]
Data processing Table B.
7.1.4
Monitor vertical displacement of front right bar bracket and enter reading in Engineer [ ]
Data processing Table B.
7.1.5
Gradually and progressively remove the load. Test Op. [ ]
7.1.6
Wait 5 min., then read permanent shift at points under test and enter readings in Engineer [ ]
Data processing Table B.
7.1.7
Repeat test adopting the same procedure, applying load to rear roof rack bar. Test Op. [ ]
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

ONLY VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

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7.2
Longitudinal horizontal load

7.2.1
Apply 4 x max. permitted load (design load) to center and top of roof bar in Engineer [ ]
direction of forward travel. Test Op. [ ]
Note: Load applied gradually and progressively over a period of between 60 and 65 seconds.
7.2.2
Apply load for 10 min. Test Op. [ ]
7.2.3
Monitor total movement at load application point. Engineer [ ]
Monitor longitudinal displacement of right bracket securing front and rear roof
rack bars (area of retention to roof) and enter reading in Data processing
Table C.
7.2.4
Gradually and progressively remove the load. Test Op. [ ]
7.2.5
Wait 5 min., then read permanent shift at points under test and record readings Engineer [ ]
in Data processing Table C.

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE THE ONLY
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

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7.3
Longitudinal horizontal load at 20 degrees

7.3.1
Repeat operations and tests specified for longitudinal horizontal load condition Engineer [ ]
but applying load at 20 degrees to direction of forward travel. Test Op. [ ]
Enter results in “Data processing” Table D.
Note: Displacements are to be monitored in direction of load application.
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

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7.4
Horizontal transverse load

7.4.1
Apply 2 x max. permissible load (design load) to roof bar at center and top of Engineer [ ]
mockup in a horizontal transverse direction outward from center. Test Op. [ ]
Note: Load applied gradually and progressively over a period of between 30 and 35 seconds.
7.4.2
Apply load for 10 min. Test Op. [ ]
7.4.3
Monitor total displacement at load application point and enter reading in Engineer [ ]
Data processing Table E.
7.4.4
Monitor transverse displacement of front and rear bar right bracket (area of Test Op. [ ]
retention to roof) and enter reading in Data processing Table E.
Gradually and progressively remove the load.
7.4.5
Wait 5 min., then read permanent shift at points under test and record readings Engineer [ ]
in Data processing Table E.

WITHOUT PRIOR WRITTEN CONSENT BY FIAT AUTO S.P.A. IN CASE OF DISPUTE THE ONLY
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

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DATA PROCESSING

8.1
Table A – Roof bar installability/removability

Fastener tightening torque data: All-purpose bar

Bolts Torque Result

Mountings
No. Type Initial Final Pass Fail

RH SIDE [ ] [ ]
FRONT
LH SIDE [ ] [ ]

RH SIDE [ ] [ ]
REAR
LH SIDE [ ] [ ]

8.1.1
Acceptability limits
• Roof bar installability/removability:
easy to perform without damaging vehicle
• Vehicle roof/roof bar:
no paint scratching
• Retaining bolts:
Torque decay at end of test < 20% of initial torque.
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

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8.2
Table B

Vertical load on all-purpose bar - daN

Displacement Result
Bar Test point
Total Perman. Pass Fail

A) Load application point (front bar C/L) [ ] [ ]

Front B) Front right bracket of roof bar (area [ ] [ ]
of retention to roof)
A) Load application point (rear bar C/L) [ ] [ ]
Rear B) Rear right bracket of roof bar (area of [ ] [ ]
retention to roof)

8.2.1
Acceptability limits
• Load application point:
- Total distortion < 20 mm
- Permanent distortion < 4 mm
• All-purpose bar front/rear bracket:
- Total distortion < 6 mm
- Permanent distortion < 2 mm
- No paint scratching
• Vehicle roof:
- No paint scratching

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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

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8.3
Table C

Longitudinal load, direction of forward travel - daN

Displacement Result
Test point
Total Perman. Pass Fail

A) Point of load application (center of mockup) [ ] [ ]

B) Roof bar front right bracket (area of retention to roof) [ ] [ ]

C) Roof bar rear right bracket (area of retention to roof) [ ] [ ]

8.3.1
Acceptability limits
• Load application point:
- Total distortion < 15 mm
- Permanent distortion < 4 mm
• All-purpose bar front/rear bracket:
- Total distortion < 5 mm
- Permanent distortion < 2 mm
- No paint scratching
• Vehicle roof:
- No paint scratching
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

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8.4
Table D

Horizontal longitudinal load at 20° – daN

Displacement Result
Test point
Total Perman. Pass Fail

A) Point of load application (center of mockup) [ ] [ ]

B) Roof bar front right bracket (area of retention to roof) [ ] [ ]

C) Roof bar rear right bracket (area of retention to roof) [ ] [ ]

8.4.1
Acceptability limits
• Load application point:
- Total distortion < 15 mm
- Permanent distortion < 4 mm
• All-purpose bar front/rear bracket:
- Total distortion < 5 mm
- Permanent distortion < 2 mm
- No paint scratching
• Vehicle roof:
- No paint scratching

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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

VALID REFERENCE IS THE ORIGINAL ITALIAN EDITION.

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8.5
Table E

Transverse load - daN

Displacement Result
Test point
Total Perman. Pass Fail

A) Point of load application (center of mockup) [ ] [ ]

B) Roof bar front right bracket (area of retention to roof) [ ] [ ]

C) Roof bar rear right bracket (area of retention to roof) [ ] [ ]

8.5.1
Acceptability limits
• Load application point:
- Total distortion < 12 mm
- Permanent distortion < 2.5 mm
• All-purpose bar front/rear bracket:
- Total distortion < 3 mm
- Permanent distortion < 1.5 mm
- No paint scratching
• Vehicle roof:
- No paint scratching
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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES

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POST-TESTING PROCEDURE

9.1
After static testing, remove roof bar assembly and monitor tightening torque of Engineer [ ]
fasteners securing brackets to roof and bars to brackets. Enter readings in
Data processing Table A.
9.2
Enter roof bar removability notes in Data processing Table A. Engineer [ ]
9.3
Place roof bar kit with attached identification card in appropriate store. Test Op. [ ]

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