GB/T 5374-2023 PDF in English
GB/T 5374-2023 (GB/T5374-2023, GBT 5374-2023, GBT5374-2023)
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Test method of reliability for motorcycles and mopeds
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| GB/T 5374-2008 | English | 519 |
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Test method of reliability for motorcycles and mopeds
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| GB/T 5374-1995 | English | 279 |
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Test method of reliability for motorcycles and mopeds
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| GB 5374-1985 | English | 279 |
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Test method of reliability and durability for motorcycles
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Standards related to (historical): GB/T 5374-2023
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GB/T 5374-2023: PDF in English (GBT 5374-2023) GB/T 5374-2023
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 43.140
CCS T 80
Replacing GB/T 5374-2008
Test method of reliability for motorcycles and mopeds
ISSUED ON: MARCH 17, 2023
IMPLEMENTED ON: OCTOBER 01, 2023
Issued by: State Administration for Market Regulation;
Standardization Administration of the People’s Republic of China.
Table of Contents
Foreword ... 3
1 Scope ... 5
2 Normative references ... 5
3 Terms and definitions ... 6
4 Test conditions ... 7
5 Test procedure ... 8
6 Test data processing ... 16
7 Test report ... 20
Appendix A (Normative) Routine operation ... 21
Appendix B (Informative) Failure classification principle ... 22
Appendix C (Informative) Customer usage correlation proving ground road driving
reliability test specification design ... 23
Appendix D (Normative) Vehicle daily operation inspection items and reliability
driving records ... 26
Appendix E (Informative) Test record form ... 28
Test method of reliability for motorcycles and mopeds
1 Scope
This document specifies the test conditions, test procedure, test data processing and test
report for the reliability test of motorcycles and mopeds.
This document applies to the reliability test of motorcycles and mopeds (unless
otherwise specified, hereinafter referred to as “motorcycles”).
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
version corresponding to that date is applicable to this document; for undated references,
the latest version (including all amendments) is applicable to this document.
GB 4569, Limit and measurement method of noise emitted by stationary -
Motorcycles and mopeds
GB/T 5359.1, Term for motorcycles and mopeds - Part 1: Types of vehicles
GB/T 5373, Measuring method of dimensions and masses parameter for motorcycles
and mopeds
GB/T 5378, Methods of road test for motorcycles and mopeds
GB/T 7031, Mechanical vibration - Road surface profiles - Reporting of measured
data
GB 7258, Technical specifications for safety of power-driven vehicles operating on
roads
GB 14622, Limits and measurement methods for motorcycle pollutant discharge
(China stage IV)
GB 15742, Performance requirements and test methods of horn for motor vehicles
GB 15744, The limits and measurement methods of fuel consumption for
motorcycles and mopeds
GB 16169, Limit and measurement method of noise emitted by accelerating -
Motorcycles and mopeds
GB 18176, Limits and measurement methods for emissions of pollutants from
mopeds (CHINA IV)
GB/T 18387, Limits and test method of magnetic and electric field strength from
electric vehicles
GB 20073, Performance and measurement method for braking of motorcycles and
mopeds
GB 24155, Safety specifications for electric motorcycles and electric mopeds
GB/T 24156, Electric motorcycles and electric mopeds - Power performance - Test
methods
GB/T 24157, Test methods of range and indication for the state of charge for electric
motorcycles and electric mopeds
GB 34660, Road vehicles - Requirements and test methods of electromagnetic
compatibility
JTG B01, Technical standard of highway engineering
QC/T 903, Fault-types for motorcycles and mopeds
3 Terms and definitions
Terms and definitions determined by GB/T 5359.1, and the following ones are
applicable to this document.
3.1 Reliability
The ability of motorcycles to ensure specified functions and technical and economic
indicators under specified conditions of use and within a specified period of time.
3.2 Customer usage correlation
Reproduce the working load of the target user on the proving ground or on the test
bench.
3.3 General reliability test
Reliability test carried out according to certain specifications on general roads.
3.4 Accelerated reliability test
Reliability test – with a certain strengthening factor – that is carried out on the proving
ground or on the test bench according to customer usage correlation.
4.2.4 Before the performance test, the vehicle under test shall be run-in and maintained
according to the instruction manual or the manufacturer’s product technical documents.
During the test, the parts and assemblies shall not be adjusted or replaced at will, and
detailed driving inspection records shall be made.
4.2.5 If the driving range of electric motorcycles and electric mopeds (hereinafter
referred to as “electric motorcycles”) is too short (less than 30 km), the battery pack
can be replaced for testing, which shall be recorded.
4.3 Test conditions for termination
If any of the following situations is found during the test, the test shall be terminated.
a) Steering, braking and other systems cannot ensure driving safety.
b) The frame or its welds are broken, de-soldered or otherwise damaged, so that the
test cannot be continued.
c) The assembly to be assessed in the test is severely damaged and needs to be
replaced.
4.4 Test road
4.4.1 The driving road for the reliability test shall generally include:
a) Urban road: main streets of communication in large and medium-sized cities; the
unevenness of the road surface shall be above grade C specified in GB/T 7031;
b) Expressway: multi-lane highway – meeting the requirements of JTG B01 – that
is exclusively for motor vehicles to drive in different directions and lanes, and
where all access and exit are controlled;
c) Ordinary highway: in line with the requirements of the national primary and
secondary highway, of wide and straight road surface, and good vision;
d) Mountain road: average slope greater than 4%, unevenness of road surface above
grade C specified in GB/T 7031.
4.4.2 The reliability test can be carried out on a closed road in the proving ground, or
on a road section with small traffic flow, which is convenient for driving speed and is
conducive to the safety of the test. When conditions permit, the road surface for the
reliability test can also be used for an accelerated reliability test to shorten the test cycle.
5 Test procedure
5.1 Vehicle parameter measurement and adjustment
5.1.1 Measurement of vehicle dimensions and masses parameter
Carry out measurement of vehicle dimensions and masses parameters in accordance
with the methods determined in GB/T 5373.
5.1.2 Key torque measurement and adjustment
According to the requirements of product technical documents provided by the
manufacturer, measure and adjust the torque of fasteners in key parts.
5.1.3 Running-in
5.1.3.1 Before running-in, check the indicated value of the speedometer according to
the provisions of GB/T 5378, and use it to correct the relevant mileage.
5.1.3.2 The vehicle under test shall run in on a flat road according to the provisions of
the product technical documents. The running-in mileage of motorcycles shall not
exceed 1 000 km; the running-in mileage of mopeds shall not exceed 250 km. It can
also be run-in to the specified mileage according to the requirements of the
manufacturer’s product technical documents.
5.1.3.3 During the running-in period, the fastening and working conditions of each part
of the vehicle shall be checked frequently, and any failure found shall be eliminated in
time and included in the failure statistics.
5.2 Vehicle performance test
5.2.1 Inspection before performance test
After running-in, maintain according to product technical documents, and drive no
longer than 50 km for inspection, so that the vehicle under test is in good mechanical
condition.
5.2.2 Vehicle performance test content
5.2.2.1 The performance test content of the motorcycle with internal combustion engine
is as follows:
a) starting performance test, carried out according to GB/T 5378;
b) maximum speed test, carried out according to GB/T 5378;
c) minimum stable speed test, carried out according to GB/T 5378;
d) acceleration performance test, carried out according to GB/T 5378;
e) sliding distance test, carried out according to GB/T 5378;
f) gradeability test, carried out according to GB/T 5378;
g) measurement of noise emitted by stationary, carried out according to GB 4569;
Brake to stop at least twice every 50 km or 1 h.
5.3.1.2.4 Driving on mountain road
When driving on a mountain road, stop and start uphill at least once every 100 km; use
the service brake to stop on a slope not less than 7%; put the transmission in neutral;
then, use the parking brake to stop (if equipped); then, proceed hill starting as normal.
5.3.1.2.5 Driving at night
The mileage ratio at night shall not be less than 10% of the total mileage of the test.
Driving with lights on during the day is allowed instead.
5.3.1.3 Driving specifications
5.3.1.3.1 Reliability test includes routine operation and reliability driving test on
various roads.
5.3.1.3.2 Routine operation items and requirements shall be in accordance with the
provisions in Appendix A. During the specific test, appropriate adjustments can be
made according to different vehicle models and test purposes.
5.3.1.3.3 All kinds of roads shall be composed of loops in proportion as much as
possible, and be mixed for driving.
5.3.1.3.4 During the driving test, the vehicle under test shall be inspected, adjusted and
maintained in accordance with the product technical conditions or the regulations in the
instruction manual. All kinds of failures and replacement of parts (other than those
specified in the technical documents or instruction manuals attached to the vehicle)
shall be included in the failure statistics. See B.1 of Appendix B for failure classification
principles. See B.2 for failure modes and classification.
5.3.2 Accelerated reliability test
5.3.2.1 Test mileage distribution
According to the customer usage correlation (see Appendix C) or the proving ground
specification, determine the mileage and working condition distribution of the test
vehicle on different types of roads in the proving ground.
5.3.2.2 Driving operation
According to the customer usage correlation, determine the driving operation of
different roads in the proving ground, and reproduce the driving conditions of different
roads.
5.3.3 Daily operation of the vehicle
According to the vehicle configuration, carry out daily operation inspection in
accordance with Appendix D, and make appropriate adjustments according to different
vehicle models and test purposes during specific tests. Operate according to the
instruction manual of the motorcycle product to ensure the normal operation of the
vehicle. For special functions in the configuration, e.g., driving modes (such as sports
mode, economic mode or snow mode), it is necessary to perform corresponding
operations in the driving test according to the requirements of the product instruction
manual.
5.4 Discovery, judgment and handling of failure
5.4.1 Basic principles
Failures are generally judged by senses, and for failures that are not easy to judge,
determine by other auxiliary means (such as marking, non-destructive testing).
5.4.2 Failure discovery
Ways to find failures include:
-- Pick-up inspection: check according to 5.3.3 daily operation of the vehicle;
-- Parking inspection: carry out regular parking inspection, mainly checking the
looseness, leakage and damage of various parts;
-- Inspection during driving: pay attention to the working condition of the
motorcycle, and stop and check if there is any abnormality;
-- Regular maintenance inspection: during maintenance operations, in addition to
item-by-item maintenance according to regulations, attention shall also be paid to
checking for abnormal phenomena, such as wear, cracks, and deformation of parts
and assemblies;
-- Performance testing and vehicle breaking inspections.
5.4.3 Failure judgment
According to the failure classification principles in Appendix B, perform failure
classification and failure mode judgment according to the method described in QC/T
903.
5.4.4 Failure handling
5.4.4.1 The vehicle, in case of failure, shall be stopped immediately for inspection. In
principle, the failure shall be eliminated in time.
-- Failure mileage: the difference between the odometer reading when the failure is
found and the odometer reading during sampling multiplied by the odometer
correction coefficient;
-- Failure description: use simple and clear language to describe the failure
phenomenon, and write down the specific value for all possible quantitative
descriptions. If necessary, draw a schematic diagram or take a photo, and indicate
the shape and size of the failure location, etc.;
-- Failure cause analysis: determine the cause of the failure through observation and
analysis, as well as size measurement, etc. of the failure phenomenon. The failure
causes include vehicle factors and human factors, and vehicle factors can be
further divided into design problems and manufacturing problems;
-- Failure consequences: parking, performance degradation, traffic accidents, etc.;
-- Handling measures: specific troubleshooting methods;
-- Failure run-out time: including waiting time, diagnosis time, repair time,
debugging time, etc.
5.6.5 Maintenance record
During the test, when performing maintenance, the vehicle information and the
maintenance record form shall be filled out (see Table E.4).
5.6.6 Replacement record
If it is necessary to replace parts or update software for the vehicle due to repair,
maintenance or other reasons, it shall be noted in the driving record form (see Table
D.2).
5.6.7 Dismantling and inspection record
5.6.7.1 During and after the motorcycle test, to check the wear and other abnormal
phenomena of the internal structure of each assembly, the main assembly (including
body, power transmission system, steering system, brake system, etc.) can be partially
or completely dismantled and inspected according to the corresponding regulations,
which shall be recorded.
5.6.7.2 The specific item content and requirements are in accordance with the product
maintenance manual. If there are special requirements for personnel qualification on
dismantling and inspection of some assemblies, professionals shall be arranged for
dismantling and inspection, and shall sign on the dismantling and inspection record.
5.6.7.3 The detection method is generally sensory evaluation. Relevant measurements
shall be carried out according to actual needs, which may include but not limited to:
appearance, wear and deformation of moving parts, etc.
5.6.7.4 The failures found during dismantling and inspection shall be included in the
failure statistics, and the time of dismantling and inspection shall be included in the
repair time.
6 Test data processing
6.1 Test statistics
After the test, failure statistics and reliability statistics shall be carried out. For related
examples, see Appendix E.
6.2 Failure statistics
6.2.1 All failures, for each vehicle, shall be filled in the failure statistics table (see Table
E.5) according to the order of the mileage in which the failure is found.
6.2.2 Failures that have not been eliminated through improvement measures shall be
counted only once; the failure categories shall be classified according to the most
serious situation, and the corresponding mileage is the failure mileage.
6.2.3 Failures of different parts with the same mileage shall be counted separately.
Failures of different modes in the same part shall also be counted separately; if several
failures of the same mode occur in the same part, only one count shall be made, and the
failure category shall be filled according to the most serious one.
6.3 Reliability statistics
6.3.1 Evaluation indicators
According to the calculation needs of the evaluation indicators, count the frequency of
various failures, the average first failure mileage, the actual driving mileage, the
average speed of the test, the troubleshooting time, the equivalent number of failures
and the equivalent rate of failures, etc. separately for each vehicle (see Table E.6).
6.3.2 Evaluation indicator calculation
6.3.2.1 Equivalent number of failures
The equivalent number of failures is calculated according to Formula (1):
Where:
rD – equivalent number of failures;
Appendix C
(Informative)
Customer usage correlation proving ground road driving reliability test
specification design
C.1 Customer usage correlation proving ground road driving reliability test
purpose and significance
Applying fatigue damage, friction loss and other theories, through typical customer
usage correlation research, formulate a proving ground reliability test plan that
represents the working conditions of typical customers of target models with a
percentile value above 90, so that in the design and development stage, the driving
conditions that are relatively consistent with typical customers can be obtained, and
then the design can be optimized to avoid “over-design” and “under-design”, to improve
the design and development efficiency, shorten the design and development cycle, and
reduce the design and development costs.
C.2 Customer usage correlation proving ground road driving reliability test
specification design process
C.2.1 According to the customer usage correlation, perform the proving ground road
driving reliability test specification design, which shall include the following contents:
a) Determine the target mileage of the model according to the design and
development targets;
b) Identify factors affecting vehicle reliability, and obtain user characteristic
information such as road types and mileage ratios, loading conditions, and driving
operations through user surveys, user vehicle data collection, and other forms;
c) According to the customer usage correlation, collect the real vehicle social road
load spectrum data and determine the benchmark load;
d) Perform acquisition of road load spectrum data on the proving ground for the
arrangement, combination and optimization of the proving ground’s characteristic
roads, vehicle speed, loading and driving operations;
e) According to the actual situation of the proving ground, carry out the specification
design of the road driving test on the proving ground.
C.2.2 See Figure C.1 for the customer usage correlation proving ground road driving
reliability test specification design process. See Table C.1 for an example of the
distribution of working conditions for accelerated reliability tests at the proving ground,
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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