Test Input Document (TID)

Common inputs for all test types

TEST TYPE Full Vehicle Tests
TEST SUB TYPE WITH LOAD CASE NO. FC 5 - 64 Kmph 40% offset frontal impact (ENCAP)
REFERENCE TEST ID:

IMPACT SIDE: (LH/RH) RH TARGET TEST SPEED(km/h) 64.0

VEHICLE MODEL ID: NEXON 1.5 Crail AMT Fearless 3G CATEGORY: M1

MODEL YEAR 2023
Full Vehicle Details
Export/Domestic version (for BM vehicles) Domestic version
Vehicle Width : Front
1540.0 mm
(Without Mirror) 1811.0 mm Wheel Track : Rear
1530.0 mm
Engine Type: 1.5 RTQ BS6 PH2
Primary Fuel Type: Diesel Primary Fuel Tank Capacity (L): 44.0
Secondary Fuel Type: Secondary Fuel Tank Capacity (L):
Wheel Details Front Rear Spare
Tyre Size (mm) 215/60 R16 Tubeless 215/60 R16 Tubeless 195/60 R16 Steel wheel
Pressure - Unladen (psi) 32.0 32.0 32.0
Pressure - Laden or Test weight (psi) 32.0 32.0 32.0
Wheel Rim Type 16" Alloy 16" Alloy Steel wheel
Remark

Specified Weights (kg) Unladen Reference Test Weight

FAW 867
RAW 503
Total Weight 1370
Note:s Default 25 kg for instrumentation will be considered in test weight.

Ride Height (Height of vehicle part from ground)

Unladen Reference Test Weight

Location
LH Front RH Front LH Rear RH Rear LH Front RH Front LH Rear RH Rear

Wheel arch top to wheel center

406 406 409 409
*Sub frame front most top part height from the
ground
* Front & Rear Crash member top height from
ground
Please provide sketch or photo for the exact measurement location
Note*:For pedestrian test:Normal ride attitude ride height = unladen weight+75kg mass on driver + 75kg on Co-Driver

Pedestrian Tests
Impact point location(first point of contact) along with Coordinates in VCS(Plz
attach a separate sheet if needed) X: Y: Z:
Contact switch locations Plz. Refer MDM Test Equipment list
If actual ride heights don’t match with design zone marking/test to be done at
actual or design ride heights.

UPD Tests
Vehicle GVW
Part drawing of UPD with loading points marked
Assembly drawing of UPD to be attached

Rear most /front most point of the vehicle marked as per IS in drawing

Frontal Pendulum Tests

Impact point details ( ‘R’ – 50 mm) with respect to long member or front cross
member top face.Plz attach image also

BIW Details
Version
BIW Details:
Variant
Kerb weight Details (Please attach the
weight matrix)
Side to be tested- LH/RH (For roof crush)
Door to be tested (LH Side)
Door to be tested (RH Side)
Duration of load application(05 secs/10secs)
 Steering System
Steering column
Assistance Electric power (EPAS) Power Assistance Type Electric (70Amp)
Inclination Type Adjustable
Design Inclination Angle 29.0 (deg)
Inclination Adjustment Range 26.9 to 32.2 degree (deg)
Telescopic (mm) Non Adjustable
Telescopic Stroke mm
Upper column mounting bolts torque 25Nm (N-m)
Lower column mounting bolts torque 20Nm (N-m)
Steering column angle for test (Tilt/Telescopic) (deg)
Top Spindle Collapsible
Make M/S Mando Stroke 60.0 mm
Break-out load (kN) Ride-down load (kN)
Bottom Spindle Collapsible
Make M/S Mando Stroke 60 mm
Break-out load (kN) Ride-down load (kN)
Steering Wheel
No. of Spokes 2 Diameter 360 mm
Steering wheel type(Air bag/non-Airbag) Airbag
X Y Z
Steering column top at design inclination (mm)
887.67 345.0 748.72
Distance in Z direction from Stg. column tip to R point mm
Steering wheel to steering column mounting bolt torque 45.0 (kg-m)

If test is to be done with airbag deployed, plz mention following details

Deployment depth mm
Time for full inflation ms
Steering column part and assembly drawing attached? false

Seating systems
No of rows 2
1st row 2nd row 3rd row
Design Specifications Driver seat Co Driver LH OB Mid RH OB LH OB Mid RH OB
Seat type Bucket Bench
No. of seating locations 2 3
Torso angle at R-point (Deg) 25.0 25.0 25.0 23.0 25.0
Seat back angle(Deg)
X 1315.0 1315.0 2097.0 2087.0 2097.0
R-point (mm) Y 345.0 -345.0 -340.0 -9.0 340.0
Z 355.0 355.0 355.0 365.0 355.0
X 1233.2 1215.0
Reference H-pt at Test
Y 345.0 -345.0
location (mm)
Z 332.0 362.0
Fore-aft stroke 200.0 200.0
Height adjustment stroke 60.0
Seat mounting bolts specifications
Size M8 M8 M8 x 1.25 M8 x 1.25
Length (mm) 20.0 20.0 25.0 25.0
Front - Inboard Grade 10.9 10.9 8.8 8.8
Washer size - - M8 - 3D M8 - 3D
Tightening torque (N-m) 25.0 25.0 25.0 25.0
Size M8 M8 M8 x 1.25 M8 x 1.25
Length (mm) 20.0 20.0 25.0 25.0
Front -Outboard Grade 10.9 10.9 8.8 8.8
Washer size - - M8 - 3D M8 - 3D
Tightening torque (N-m) 25.0 25.0 25.0 25.0
Size M8 M8 M8 x 1.25 M8 x 1.25
Length (mm) 20.0 20.0 25.0 25.0
Rear - Inboard Grade 10.9 10.9 8.8 8.8
Washer size - - M8 - 3D M8 - 3D
Tightening torque (N-m) 25.0 25.0 25.0 25.0
Size M8 M8 M8 x 1.25 M8 x 1.25
Length (mm) 20.0 20.0 25.0 25.0
Rear - Outboard Grade 10.9 10.9 8.8 8.8
Washer size - - M8 - 3D M8 - 3D
Tightening torque (N-m) 25.0 2.5 25.0 25.0
Support structure specifications
Size
Length (mm)
LH Mounting Grade
Washer size
Tightening torque (N-m)
 Size
Length (mm)
RH Mounting Grade
Washer size
Tightening torque (N-m)
Seat weight with tolerance (kg) 19.4 15.3 27
For/aft Mid Mid NA
Seat position for test Height adjustment Low NA
Seat Back
2 point or 3 point belt ? 3 Point 3 Point 3 Point 2 Point 3 Point
Top On BIW On BIW On BIW On BIW
Location of SBA Bottom On BIW On BIW 7/16
On BIW20 On BIW 7/16
On BIW20
(BIW/Seat+BIW) Buckle On Seat On Seat UNF Bolt
On BIW On BIW UNF Bolt
On BIW
7/16 20 UNF Bolt 7/16 20 UNF Bolt A/F 14mm A/F 14mm
ELR OnFlat
Across BIWWidth OnFlat
Across BIWWidth 8On BIW
Grade On
8 BIW
Grade
Top 14mm Length: 31 14mm Length: 31 Length: 24 Length: 24

7/16 20 7/16 20 7/16 20

7/16 20 UNF Bolt 7/16 20 UNF Bolt UNF Bolt UNF Bolt UNF Bolt
Across Flat Width Across Flat Width A/F 14mm A/F 14mm A/F 14mm
14mm Length: 31 14mm Length: 31 8 Grade 8 Grade 8 Grade
Length: 24 Length: 24 Length: 24
Bottom

7/16 20 7/16 20 7/16 20

SBA bolts Specs. 7/16 20 UNF Bolt 7/16 20 UNF Bolt UNF Bolt UNF Bolt UNF Bolt
(Size/Length/Grade) Across Flat Width Across Flat Width A/F 14mm A/F 14mm A/F 14mm
14mm Length: 25 14mm Length: 25 8 Grade 8 Grade 8 Grade
Length: 24 Length: 24 Length: 24
Buckle

7/16 20 7/16 20
7/16 20 UNF Bolt 7/16 20 UNF Bolt UNF Bolt UNF Bolt
Across Flat Width Across Flat Width A/F 14mm A/F 14mm
14mm Length: 31 14mm Length: 31 8 Grade 8 Grade
Length: 24 Length: 24
ELR
SBA bolts tightening torque (N-m) 45.0 45.0 45.0 45.0 45.0
Effective top anchorage displacement limit. (10˚
FORWARD TO ‘R’ PT.)
(if top SBA is on seat)
NA NA NA
Location of ISOFIX NA NA On BIW On BIW On BIW
Location of top tether NA NA On BIW On BIW On BIW

false false false

Seat belt routing & mounting drawings Attached

Driver Seat Co Driver Seat

H-point envelop
co-ordinates X Y Z X Y Z
Pt 1 1281.7 345.0 384.8
Pt 2 1315.0 345.0 355.0
Pt 3 1333 345.0 325.0
Pt 4 1181.95 345.0 391.9
Pt 5 1215.25 345.0 362.0
Pt 6 1233.15 345.0 332.0
Pt 7 1082.2 345.0 399
Pt 8 1115.5 345.0 369.0
Pt 9 1133.3 345.0 339.0
Pt 10 1315.0 -345.0 355.0
Pt 11 1215.0 -345.0 362.0
Pt 12 1115.5 -345.0 369.0
REMARK : Refer below image for seat adjustment envelop

Interior Trims
Interior Trims
Mounting bolt details Size
Length(mm)
Grade
Mounting bolt details

Torque(kg-m)
Mounting angle w.r.t Horizontal
Interior fitment evaluation to be done on worst case
version/Cab?

(Note:CSA to be measured at 6.5mm from the

point projecting furthest)
Radius
6.5mm Mention
this CSA
area
Gear shift lever

Cross sectional area (cm2 )

 Element Type

AC grills Thickness of element(e)

Gap btwn elements(g)
Radius of element(R)

Cross sectional area of switches, pull knobs, AC knobs etc.

Sunvisor frame wire diameter (mm)
Ignition key coating material shore A hardness

Part level and assembly level drawing of parts to be provided

Restraints Systems
ECU & RSU
No of loops for the
ECU 12 Algorithm ID D Sample

ECU Required / Not Required Design torque on 9.0 Nm Type Functional

Screws
Design torque on
Required / Not Required 9.0 Nm Type Functional
FRONT RSU Screws
Mounting co –ordinate of FRSU: - X= 545.4 Y= 374.8 Z= 474.9
Design torque on
Required / Not Required Nm Type
SIDE RSU Screws
Mounting co –ordinate of SRSU: - X= 1391.5 Y= 764.1 Z= 341.9
Airbags
Design
torque
Mounting Bolt Size No of
on Capacity (Kpa) Vent Size (mm) FIRE time (ms)
Specification (Litres) vents
Screws
(Nm)
Nominal Backup
Min
DAB Press fitted DAB NA 55.0 195.0 2 30
Nom
Max
Nominal Backup
Min
PAB M6 x 16mm bolt 6.0 90.0 330.0 2 30
Nom
Max
Nominal Backup
Min
SAB (Driver) M6 x 16mm bolt 5.5 10 123 1 15
Nom
Max
Nominal Backup
Min
SAB (Passenger) M6 x 16mm bolt 5.5 10 123 1 15
Nom
Max
Nominal Backup
Min
IC (Driver) Clips NA 30L 267 NA NA
Nom
Max
Nominal Backup
Min
IC (Passenger) Clips NA 30L 267 NA NA
Nom
Max
Seat Belts
Specified Length of the Belt
Type Adjustable Anchorage Design Position
( mm )
Driver RPLL+CLT 3310mm Top
Co-Driver RPLL 3440mm Top
2700 +/-
Out Board Seat
25mm
2nd Row ELR Fixed
1200 +/-
Middle Seat
15mm
Out Board Seat
3rd Row
Middle Seat
For RP / RPLL belts Required / Not Required Design torque on Screws Fire Time (ms) LL value
Normal Backup
Min
Driver 45.0 76.0
Nom
Max
Normal Backup
Min
Passenger 45.0 69.0
Nom
Max
Child Restraints
Specified Locations
Fitment

Remark
 CMM co-ordinate requirements
Design co-ordinates required for CMM alignment
Location X Y Z
Front Seat belt top anchorage (RH) 1499.2 608.8 970.0
Front Seat belt retractor anchorage (RH) 1,383.1 677.9 185.0
Front Seat belt lap anchorage (RH) 1,479.3 667.0 62.7
Front seat front outboard mounting 956.7 581.5 98.0
Front seat front inboard mounting 956.7 133.5 133.0
Front seat rear outboard mounting 1330.8 581.5 71.8
Front seat rear inboard mounting 1340.8 133.5 106.1
65% Rear seat front outboard mounting
65% Rear seat front inboard mounting
65% Rear seat rear outboard mounting
65% Rear seat rear inboard mounting
35% Rear seat front outboard mounting
35% Rear seat front inboard mounting
35% Rear seat rear outboard mounting
35% Rear seat rear inboard mounting
Rear seat belt top anchorage
Rear Seat belt retractor anchorage (RH) 2,664.2 625.0 854.6
Rear Seat belt lap anchorage (RH) 2,181.2 521.9 193.3

For Pedestrian test

Location X Y Z
Fender mountings
Front end module mountings
Head lamp mountings
Bonnet latch mountings
Bonnet hinge mounting

REMARKS: (Pl. Provide image of the above mentioned points for clarity.)

Provide details if any specific vehicle points have to be digitized

Miscellaneous Inputs
1. List down if any modifications to be done, things to be removed/left on vehicle

2. List down any Specific CMM requirements, impact locations(Eg. HFI test), Dummy type and its position for test(in case of any new load case
definition), any other specific instructions.(Add image for CMM & HFI Impact locations).

3. List down all specific design changes w.r.t. earlier test (attach CAE reports, if any)

4. Circulation List (Please provide the names to whom the report to be circulated)

Mr. Makarand deval (GM, VIG - X1), Mr. Milind Tank (GM, Body & Trims)
 Ground to Wheel
Tyre Weight Details Wheel Centre to Wheel Arch
Arch
PT Specification FAW RAW Kerb Front Rear Front
1.5L Crail +MT 215/60R16 862 485 1347 406 410 714
1.2L NGTC +DCT 215/60R16 798 489 1288 405 409 715
Ground to Wheel
Arch
Rear
729
727