Commission Regulation (EU) 2017/2400 of 12 December 2017 implementing Regulation (EC) No 595/2009 of the European Parliament and of the Council as regards the determination of the CO2 emissions and fuel consumption of heavy-duty vehicles and amending Directive 2007/46/EC of the European Parliament and of the Council and Commission Regulation (EU) No 582/2011 (Text with EEA relevance. )

If multiple oils are recommended for first fill, they are considered to be equal if the oils have a kinematic viscosity within 10 % of each other at the same temperature (within the specified tolerance band for KV100). Any oil with lower viscosity than the oil used in the test shall be considered to result in lower losses for the tests performed within this option. Any additional first fill oil must fall either in the 10 % tolerance band or have lower viscosity than the oil in the test to be covered by the same certificate.

3.1.2.5.5.   Oil level and conditioning

The oil level shall meet the nominal specifications for the transmission.

If an external oil conditioning system is used, the oil inside the transmission shall be kept to the specified volume that corresponds to the specified oil level.

To guarantee that the external oil conditioning system is not influencing the test, one test point shall be measured with the conditioning system both on and off. The deviation between the two measurements of the torque loss (= input torque) shall be less than 5 %. The test point is specified as follows:

• (1) gear = highest indirect gear,

• (2) input speed = minimum of 60 % of the maximum input speed, not higher than 80 % of the maximum input speed,

• (3) temperatures as specified under 3.1.2.5.

For transmissions with hydraulic pressure control or a smart lubrication system, the measurement of torque independent losses shall be performed with two different settings: first with the transmission system pressure set to at least the minimum value for conditions with engaged gear and a second time with the maximum possible hydraulic pressure (see 3.1.6.3.1).

• 3.1.3. Installation

• 3.1.3.1. The electric machine and the torque sensor shall be mounted to the input side of the transmission. The output shaft(s) shall rotate freely. In the case of a transmission with an integrated differential, e.g. for front-wheel drive operation, the output ends shall be allowed to be rotatably locked into each other (e.g. by an activated differential lock or by means of any other mechanical differential lock implemented only for the measurement).

• 3.1.3.2. The installation of the transmission shall be done with an angle of inclination as for installation in the vehicle according to the homologation drawing ± 1° or at 0° ± 1°.

• 3.1.3.3. The internal oil pump shall be included in the transmission.

• 3.1.3.4. If an oil cooler is either optional or required with the transmission, the oil cooler may be excluded in the test or any oil cooler may be used in the test.

• 3.1.3.5. Transmission testing can be done with or without power take-off drive mechanism and/or power take-off. For establishing the power losses of power take-offs and /or power take-off drive mechanism, the values in  Annex IX to this regulation are applied. These values assume that the transmission is tested without power take-off drive mechanism and /or power take-off.

• 3.1.3.6. Measuring the transmission may be performed with or without single dry clutch (with one or two plates) installed. Clutches of any other type shall be installed during the test.

• 3.1.3.7. The individual influence of parasitic loads shall be calculated for each specific test rig setup and torque sensor as described in 3.1.8.

• 3.1.4. Measurement equipment

The calibration laboratory facilities shall comply with the requirements of either  IATF 16949, ISO 9000 series or ISO/IEC 17025. All laboratory reference measurement equipment, used for calibration and/or verification, shall be traceable to national (international) standards.

3.1.4.1.   Torque

The torque sensor measurement uncertainty shall be below 0,3 Nm.

The use of torque sensors with higher measurement uncertainties is allowed if the part of the uncertainty exceeding 0,3 Nm can be calculated and is added to the measured torque loss as described in 3.1.8. Measurement uncertainty.

3.1.4.2.   Speed

The uncertainty of the speed sensors shall not exceed ± 1 rpm.

3.1.4.3.   Temperature

The uncertainty of the temperature sensors for the measurement of the ambient temperature shall not exceed ± 1,5 K.

The uncertainty of the temperature sensors for the measurement of the oil temperature shall not exceed ± 1,5 K.

3.1.4.4.   Pressure

The uncertainty of the pressure sensors shall not exceed 1 % of the maximum measured pressure.

3.1.4.5.   Voltage

The uncertainty of the voltmeter shall not exceed 1 % of the maximum measured voltage.

3.1.4.6.   Electric current

The uncertainty of the amperemeter shall not exceed 1 % of the maximum measured current.

• 3.1.5. Measurement signals and data recording

At least the following signals shall be recorded during the measurement:

• (1) Input torques [Nm]

• (2) Input rotational speeds [rpm]

• (3) Ambient temperature [°C]

• (4) Oil temperature [°C]

If the transmission is equipped with a shift and/or clutch system that is controlled by hydraulic pressure or with a mechanically driven smart lubrication system, additionally to be recorded:

• (5) Oil pressure [kPa]

If the transmission is equipped with transmission electric auxiliary, additionally to be recorded:

• (6) Voltage of transmission electric auxiliary [V]

• (7) Current of transmission electric auxiliary [A]

For differential measurements for the compensation of influences caused by the test rig setup, additionally shall be recorded:

• (8) Test rig bearing temperature [°C]

The sampling and recording rate shall be 100 Hz or higher.

A low pass filter shall be applied to reduce measurement errors.

• 3.1.6. Test procedure

3.1.6.1.   Zero torque signal compensation:

The zero-signal of the torque sensor(s) shall be measured. For the measurement the sensor(s) shall be installed in the test rig. The drivetrain of the test rig (input & output) shall be free of load. The measured signal deviation from zero shall be compensated.

3.1.6.2.   The torque loss shall be measured for the following speed points (speed of the input shaft): 600, 900, 1 200 , 1 600 , 2 000 , 2 500 , 3 000 , 4 000 rpm and multiples of 10 of these values up to the maximum speed per gear in accordance with the specifications of the transmission or the last speed point before the defined maximum speed. It is permitted to measure additional intermediate speed points.

The speed ramp (time for the change between two speed points) shall not exceed 20 seconds.

3.1.6.3.   Measurement sequence:

• 3.1.6.3.1. If the transmission is equipped with smart lubrication systems and/or transmission electric auxiliaries, the measurement shall be conducted with two measurement settings of of these systems: A first measurement sequence (3.1.6.3.2. to 3.1.6.3.4.) shall be performed with the lowest power consumption by hydraulical and electrical systems when operated in the vehicle (low loss level). The second measurement sequence shall be performed with the systems set to work with the highest possible power consumption when operated in the vehicle (high loss level).

• 3.1.6.3.2. The measurements shall be performed beginning with the lowest up to the highest speed.

• 3.1.6.3.3. For each speed point a minimum of 5-second stabilisation time within the temperature limits defined in 3.1.2.5 is required. If needed, the stabilization time may be extended by the manufacturer to maximum 60 seconds. Oil and ambient temperatures shall be recorded during the stabilization.

• 3.1.6.3.4. After the stabilisation time, the torque loss should be constant at the actual measured speed point over time. If so, the measurement signals listed in 3.1.5. shall be recorded for a minimum of 5 seconds but for no longer than 15 seconds. If the torque loss is not constant at the actual measured speed point over time, e.g. by intended periodic variation of the torque losses caused by active or passive means of control, the manufacturer shall use the testing time required to get a reproducible and representative result.

• 3.1.6.3.5. Each measurement shall be performed two times per measurement setting.

• 3.1.7. Measurement validation

• 3.1.7.1. The arithmetic mean values shall be calculated for each of the measurements of torque, speed, (if applicable) voltage and current. The measurements to be performed for a minimum of 5 seconds but for no longer than 15 seconds. If the torque loss is not constant at the actual measured speed point over time, e.g. by intended periodic variation of the torque losses caused by active or passive means of control, the manufacturer shall use the testing time required to get a reproducible and representative result.

• 3.1.7.2. The averaged speed deviation shall be below ± 5 rpm of the speed set point for each measured point for the complete torque loss series.

• 3.1.7.3. The mechanical torque losses and (if applicable) electrical power consumption shall be calculated for each of the measurements as followed:

Tloss = T1,in(nin, Tin,gear)

Pel = I * U

It is allowed to subtract influences caused by the test rig setup from the torque losses (3.1.2.2.).

• 3.1.7.4. The mechanical torque losses and (if applicable) electrical power consumption from the two sets shall be averaged (arithmetic mean values).

• 3.1.7.5. The deviation between the averaged torque losses of the two measurement points for each setting shall be below ± 5 % of the average or ± 1 Nm, whichever value is larger. Then, the arithmetic average of the two averaged power values shall be taken.

• 3.1.7.6. If the deviation is higher, the largest averaged torque loss value shall be taken or the test shall be repeated for the gear.

• 3.1.7.7. The deviation between the averaged electric power consumption (voltage * current) values of the two measurements for each measurement setting shall be below ± 10 % of the average or ± 5 W, whichever value is larger. Then, the arithmetic average of the two averaged power values shall be taken.

• 3.1.7.8. If the deviation is higher, the set of averaged voltage and current values giving the largest averaged power consumption shall be taken, or the test shall be repeated for the gear.

• 3.1.8. Measurement uncertainty

The part of the calculated total uncertainty UT,loss exceeding 0,3 Nm shall be added to Tloss for the reported torque loss Tloss,rep. If UT,loss is smaller than 0,3 Nm, then Tloss,rep = Tloss.

Tloss,rep = Tloss + MAX (0, (UT,loss – 0,3 Nm))

The total uncertainty UT,loss of the torque loss shall be calculated based on the following parameters:

• (1) Temperature effect

• (2) Parasitic loads

• (3) Calibration error (incl. sensitivity tolerance, linearity, hysteresis and repeatability)

The total uncertainty of the torque loss (UT,loss) is based on the uncertainties of the sensors at 95 % confidence level. The calculation shall be done as the square root of the sum of squares (‘Gaussian law of error propagation’).

Image omitted; see official source

Image omitted; see official source

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Image omitted; see official source

wpara = senspara * ipara

where:

Tloss	=	Measured torque loss (uncorrected) [Nm]
---	---	---
Tloss,rep	=	Reported torque loss (after uncertainty correction) [Nm]
---	---	---
UT,loss	=	Total expanded uncertainty of torque loss measurement at 95 % confidence level [Nm]
---	---	---
UT,in	=	Uncertainty of input torque loss measurement [Nm]
---	---	---
uTKC	=	Uncertainty by temperature influence on current torque signal [Nm]
---	---	---
wtkc	=	Temperature influence on current torque signal per Kref, declared by sensor manufacturer [%]
---	---	---
uTK0	=	Uncertainty by temperature influence on zero torque signal (related to nominal torque) [Nm]
---	---	---
wtk0	=	Temperature influence on zero torque signal per Kref (related to nominal torque), declared by sensor manufacturer [%]
---	---	---
Kref	=	Reference temperature span for uTKC and uTK0, wtk0 and wtkc, declared by sensor manufacturer [K]
---	---	---
ΔK	=	Difference in sensor temperature between calibration and measurement [K]. If the sensor temperature cannot be measured, a default value of ΔK = 15 K shall be used.
---	---	---
Tc	=	Current/measured torque value at torque sensor [Nm]
---	---	---
Tn	=	Nominal torque value of torque sensor [Nm]
---	---	---
ucal	=	Uncertainty by torque sensor calibration [Nm]
---	---	---
Wcal	=	Relative calibration uncertainty (related to nominal torque) [%]
---	---	---
kcal	=	Calibration advancement factor (if declared by sensor manufacturer, otherwise = 1)
---	---	---
upara	=	Uncertainty by parasitic loads [Nm]
---	---	---
wpara	=	senspara * ipara Relative influence of forces and bending torques caused by misalignment
---	---	---
senspara	=	Maximum influence of parasitic loads for specific torque sensor declared by sensor manufacturer [%]; if no specific value for parasitic loads is declared by the sensor manufacturer, the value shall be set to 1,0 %
---	---	---
ipara	=	Maximum influence of parasitic loads for specific torque sensor depending on test setup (A/B/C, as defined below).
---	---	---
	=	A) 10 % in case of bearings isolating the parasitic forces in front of and behind the sensor and a flexible coupling (or cardan shaft) installed functionally next to the sensor (downstream or upstream); furthermore, these bearings can be integrated in a driving/braking machine (e.g. electric machine) and/or in the transmission as long as the forces in the machine and/or transmission are isolated from the sensor. See figure 1. Figure 1 Example of test setup A for Option 1 Image omitted; see official source Text of image Test setup A INPUT E: Electric machine T: Torque sensor F: Flexible coupling B: Bearing TM: Transmission
---	---	---
	=	B) 50 % in case of bearings isolating the parasitic forces in front of and behind the sensor and no flexible coupling installed functionally next to the sensor; furthermore, these bearings can be integrated in a driving/braking machine (e.g. electric machine) and/or in the transmission as long as the forces in the machine and/or transmission are isolated from the sensor. See figure 2. Figure 2 Example of test setup B for Option 1 Image omitted; see official source Text of image Test setup B INPUT E: Electric machine T: Torque sensor B: Bearing TM: Transmission
---	---	---
	=	C) 100 % for other setups

A test setup for a transmission with integrated differential for front-wheel drive operation consists of a dynamometer on the transmission input side and at least one dynamometer on the transmission output side(s). Torque measuring devices shall be installed on the transmission input- and output- side(s). For test setups with only one dynamometer on the output side, the free rotating end of the transmission with integrated differential shall be rotatably locked to the other end on the output side (e.g. by an activated differential lock or by means of any other mechanical differential lock implemented only for the measurement).

The graduation of the factor ipara for the maximum influence of parasitic loads for specific torque sensor is equal to the above described cases (A/B/C).

Figure 2A

Example of test setup A for Option 1 for a transmission with integrated differential (e.g. for front-wheel drive operation)

Image omitted; see official source

Figure 2B

Example of test setup B for Option 1 for a transmission with integrated differential (e.g. for front-wheel drive operation)

Image omitted; see official source

The manufacturer may adapt the test setups A and B based upon good engineering judgement and in agreement with the approval authority, e.g. in the case of practical test setup reasons. In the case of such a deviation, the reason and alternative setup shall be clearly specified in the test report.

It is allowed to perform the test without a separate bearing unit on the test rig at the transmission input/output side if the transmission shaft on which the torque is measured is supported by two bearings in the transmission housing which are able to absorb radial and axial forces caused by the gearsets.

Figure 2C

Example where the forces in the transmission are isolated and not isolated from the input:

Image omitted; see official source

• 3.2. Option 2: Measurement of the torque independent losses, measurement of the torque loss at maximum torque and interpolation of the torque dependent losses based on a linear model

Option 2 describes the determination of the torque loss by a combination of measurements and linear interpolation. Measurements shall be performed for the torque independent losses of the transmission and for one load point of the torque dependent losses (maximum input torque). Based on the torque losses at no load and at maximum input torque, the torque losses for the input torques in between shall be calculated with the torque loss coefficient fTlimo.

The torque loss Tl,in on the input shaft of the transmission shall be calculated by

T l,in(n in,T in,gear) = T l,in,min_loss + f Tlino × T in + T l,in,min_el + f el_corr × T in + f loss tcc × T in

The torque loss coefficient based on the linear model fTlimo shall be calculated by

Image omitted; see official source

where:

Tl,in	=	Torque loss related to input shaft [Nm]
---	---	---
Tl,in,min_loss	=	Drag torque loss at transmission input, measured with free rotating output shaft from testing without load [Nm]
---	---	---
nin	=	Speed at the input shaft [rpm]
---	---	---
fTlimo	=	Torque loss coefficient based on linear model [-]
---	---	---
Tin	=	Torque at the input shaft [Nm]
---	---	---
Tin,maxT	=	Maximum tested torque at the input shaft (normally 100 % input torque, refer to 3.2.5.2. and 3.4.4.) [Nm]
---	---	---
Tl,maxT	=	Torque loss related to input shaft with Tin = Tin,maxT
---	---	---
fel_corr	=	Loss correction for electric power loss level depending on input torque [-]
---	---	---
Tl,in,el	=	Additional torque loss on input shaft by electric consumers [Nm]
---	---	---
Tl,in,min_el	=	Additional torque loss on input shaft by electric consumers corresponding to minimum electric power [Nm]

The correction factor for the torque dependent electric torque losses fel_corr, the torque loss at the input shaft of the transmission caused by the power consumption of transmission electric auxiliary Tl,in,el and the loss correction factor floss_tcc for slipping TC lock-up clutch as defined in point 2(16) or slipping input side clutch as defined in 2(20) shall be calculated as described in point 3.1.

• 3.2.1. The torque losses shall be measured in accordance with the procedure described in the following.

3.2.1.1.   General requirements:

As specified for Option 1 in 3.1.2.1.

3.2.1.2.   Differential measurements:

As specified for Option 1 in 3.1.2.2.

3.2.1.3.   Run-in

As specified for Option 1 in 3.1.2.3.

3.2.1.4.   Pre-conditioning

As specified for Option 3 in 3.3.2.1.

3.2.1.5.   Test conditions

3.2.1.5.1.   Ambient temperature

As specified for Option 1 in 3.1.2.5.1.

3.2.1.5.2.   Oil temperature

As specified for Option 1 in 3.1.2.5.2.

3.2.1.5.3.   Oil quality / Oil viscosity

As specified for Option 1 in 3.1.2.5.3 and 3.1.2.5.4.

3.2.1.5.4.   Oil level and conditioning

As specified for Option 3 in 3.3.3.4.

• 3.2.2. Installation

As specified for Option 1 in 3.1.3. for the measurement of the torque independent losses.

As specified for Option 3 in 3.3.4. for the measurement of the torque dependent losses.

• 3.2.3. Measurement equipment

As specified for Option 1 in 3.1.4. for the measurement of the torque independent losses.

As specified for Option 3 in 3.3.5. for the measurement of the torque dependent losses.

• 3.2.4. Measurement signals and data recording

As specified for Option 1 in 3.1.5 for the measurement of the torque independent losses.

As specified for Option 3 in 3.3.7 for the measurement of the torque dependent losses.

• 3.2.5. Test procedure

The torque loss map to be applied to the simulation tool contains the torque loss values of a transmission depending on rotational input speed and input torque.

To determine the torque loss map for a transmission, the basic torque loss map data shall be measured and calculated as specified in this paragraph. The torque loss results shall be complemented in accordance with 3.4 and formatted in accordance with Appendix 12 for the further processing by the simulation tool.

• 3.2.5.1. The torque independent losses shall be determined by the procedure described in 3.1.1. for the torque independent losses for Option 1 only for the low loss level setting of electric and hydraulic consumers.

• 3.2.5.2. Determine the torque dependent losses for each of the gears using the procedure described for Option 3 in 3.3.6., diverging in the applicable torque range:

Torque range:

The torque losses for each gear shall be measured at 100 % of the maximum transmission input torque per gear.

In the case the output torque exceeds 10 kNm (for a theoretical loss free transmission) or the input power exceeds the specified maximum input power, point 3.4.4. shall apply.

• 3.2.6. Measurement validation

As specified for Option 3 in 3.3.8.

• 3.2.7. Measurement uncertainty

As specified for Option 1 in 3.1.8. for the measurement of the torque independent losses.

As specified for Option 3 in 3.3.9. for the measurement of the torque dependent loss.

• 3.3. Option 3: Measurement of the total torque loss.

Option 3 describes the determination of the torque loss by full measurement of the torque dependent losses including the torque independent losses of the transmission.

3.3.1.   General requirements

As specified for Option 1 in 3.1.2.1.

3.3.1.1   Differential measurements:

As specified for Option 1 in 3.1.2.2.

3.3.2.   Run-in

As specified for Option 1 in 3.1.2.3.

3.3.2.1   Pre-conditioning

As specified for Option 1 in 3.1.2.4. with an exception for the following:

The pre-conditioning shall be performed on the direct drive gear without applied torque to the output shaft or target torque on the output shaft set to zero. If the transmission is not equipped with a direct drive gear, the gear with the ratio closest to 1:1 shall be used.

or

The requirements as specified in 3.1.2.4. shall apply, with an exception for the following:

The pre-conditioning shall be performed on the direct drive gear without applied torque to the output shaft or the torque on the output shaft being within +/- 50 Nm. If the transmission is not equipped with a direct drive gear, the gear with the ratio closest to 1:1 shall be used.

or, if the test rig includes a (master friction) clutch at the input shaft:

The requirements as specified in 3.1.2.4. shall apply, with an exception for the following:

The pre-conditioning shall be performed on the direct drive gear without applied torque to the output shaft or without applied torque to the input shaft. If the transmission is not equipped with a direct drive gear, the gear with the ratio closest to 1:1 shall be used.

The transmission would then be driven from the output side. Those proposals could also be combined.

3.3.3.   Test conditions

3.3.3.1.   Ambient temperature

As specified for Option 1 in 3.1.2.5.1.

3.3.3.2.   Oil temperature

As specified for Option 1 in 3.1.2.5.2.

3.3.3.3.   Oil quality / Oil viscosity

As specified for Option 1 in 3.1.2.5.3 and 3.1.2.5.4.

3.3.3.4.   Oil level and conditioning

The requirements as specified in 3.1.2.5.5. shall apply, diverging in the following:

The test point for the external oil conditioning system is specified as follows:

• (1) highest indirect gear,

• (2) input speed = minimum of 60 %, not higher than 80 % of the maximum input speed,

• (3) input torque = maximum input torque for the highest indirect gear

3.3.4.   Installation

The test rig shall be driven by electric machines (input and output).

Torque sensors shall be installed at the input and output side(s) of the transmission.

Other requirements as specified in 3.1.3. shall apply.

3.3.5.   Measurement equipment

For the measurement of the torque independent losses, the measurement equipment requirements as specified for Option 1 in 3.1.4. shall apply.

For the measurement of the torque dependent losses, the following requirements shall apply:

The torque sensor measurement uncertainty shall be below 5 % of the measured torque loss or 1 Nm (whichever value is larger).

The use of torque sensors with higher measurement uncertainties is allowed if the parts of the uncertainty exceeding 5 % or 1 Nm can be calculated and the smaller of those parts is added to the measured torque loss.

The torque measurement uncertainty shall be calculated and included as described under 3.3.9.

Other measurement equipment requirements as specified for Option 1 in 3.1.4. shall apply.

3.3.6.   Test procedure

3.3.6.1.   Zero torque signal compensation:

As specified in 3.1.6.1.

3.3.6.2.   Speed range

The torque loss shall be measured for the following speed points (speed of the input shaft): 600, 900, 1 200 , 1 600 , 2 000 , 2 500 , 3 000 , 4 000 rpm and multiples of 10 of these values up to the maximum speed per gear according to the specifications of the transmission or the last speed point before the defined maximum speed. It is permitted to measure additional intermediate speed points.

The speed ramp (time for the change between two speed points) shall not exceed 20 seconds.

3.3.6.3.   Torque range

For each speed point the torque loss shall be measured for the following input torques: 0 (free rotating output shaft), 200, 400, 600, 900, 1 200 , 1 600 , 2 000 , 2 500 , 3 000 , 3 500 , 4 000 , […] Nm up to the maximum input torque per gear in accordance with the specifications of the transmission or the last torque point before the defined maximum torque and / or the last torque point before the output torque of 10 kNm. It is permitted to measure additional intermediate torque points. If the torque range is too small, additional torque points are required, so that at least 5 equally spaced torque points shall be measured. The intermediate torque points may be adjusted to the nearest multiple of 50 Nm.

In the case the output torque exceeds 10 kNm (for a theoretical loss free transmission) or the input power exceeds the specified maximum input power, point 3.4.4. shall apply.

The torque ramp (time for the change between two torque points) shall not exceed 15 seconds (180 seconds for option 2).

To cover the complete torque range of a transmission in the above defined map, different torque sensors with limited measurement ranges may be used on the input/output side. Therefore the measurement may be divided into sections using the same set of torque sensors. The overall torque loss map shall be composed of these measurement sections.

3.3.6.4.   Measurement sequence

• 3.3.6.4.1. The measurements shall be performed beginning with the lowest up to the highest speed.

• 3.3.6.4.2. The input torque shall be varied according to the above defined torque points from the lowest to the highest torque which is covered by the current torque sensors for each speed point.

• 3.3.6.4.3. For each speed and torque point a minimum of 5-second stabilisation time within the temperature limits defined in 3.3.3. is required. If needed, the stabilization time may be extended by the manufacturer to maximum 60 seconds (maximum 180 seconds for option 2). Oil and ambient temperatures shall be recorded during the stabilization.

• 3.3.6.4.3.1. After the stabilisation time, the torque loss should be constant at the actual measured speed point over time. If so, the measurement signals listed in 3.3.7. shall be recorded for a minimum of 5 seconds but for no longer than 15 seconds. If the torque loss is not constant at the actual measured speed point over time, e.g. by intended periodic variation of the torque losses caused by active or passive means of control, the manufacturer shall use the testing time required to get a reproducible and representative result.

• 3.3.6.4.4. The measurement set shall be performed two times in total. For that purpose, sequenced repetition of sections using the same set of torque sensors is allowed.

3.3.7.   Measurement signals and data recording

At least the following signals shall be recorded during the measurement:

• (1) Input and output torques [Nm]

• (2) Input and output rotational speeds [rpm]

• (3) Ambient temperature [°C]

• (4) Oil temperature [°C]

If the transmission is equipped with a shift and/or clutch system that is controlled by hydraulic pressure or with a mechanically driven smart lubrication system, additionally to be recorded:

• (5) Oil pressure [kPa]

If the transmission is equipped with transmission electric auxiliary, additionally to be recorded:

• (6) Voltage of transmission electric auxiliary [V]

• (7) Current of transmission electric auxiliary [A]

For differential measurements for compensation of influences by test rig setup, additionally to be recorded:

• (8) Test rig bearing temperature [°C]

The sampling and recording rate shall be 100 Hz or higher.

A low pass filter shall be applied to avoid measurement errors.

3.3.8.   Measurement validation

• 3.3.8.1. The arithmetic mean values of torque, speed, if applicable voltage and current for the measurement for a minimum of 5 seconds but for no longer than 15 seconds shall be calculated for each of the two measurements. If the torque loss is not constant at the actual measured speed point over time, e.g. by intended periodic variation of the torque losses caused by active or passive means of control, the manufacturer shall use the testing time required to get a reproducible and representative result.

• 3.3.8.2. The measured and averaged speed at the input shaft shall be below ± 5 rpm of the speed set point for each measured operating point for the complete torque loss series.  The measured and averaged torque at the input shaft shall be below ± 5 Nm or ±  1,0 % of the torque set point whichever value is larger for each measured operating point for the complete torque loss series.

• 3.3.8.3. The mechanical torque losses and (if applicable) electrical power consumption shall be calculated for each of the measurements as followed:

Image omitted; see official source

In the case of a transmission with integrated differential and a dynamometer on each output shaft, the total mechanical torque loss (Tloss) shall be calculated by:

Image omitted; see official source

The correction factor for the loss correction floss_tcc for slipping TC lock-up clutch or slipping input side clutch in accordance with the definitions (16) and (20) shall be calculated as described in point 3.1.

It is allowed to subtract influences caused by the test rig setup from the torque losses (in accordance with section 3.1.2.2.).

• 3.3.8.4. The mechanical torque losses and (if applicable) electrical power consumption from the two sets shall be averaged (arithmetic mean values).

• 3.3.8.5. The deviation between the averaged torque losses of the two measurement sets shall be below ± 5 % of the average or ± 1 Nm (whichever value is larger). The arithmetic average of the two averaged torque loss values shall be taken. If the deviation is higher, the largest averaged torque loss value shall be taken or the test shall be repeated for the gear.

• 3.3.8.6. The deviation between the averaged electric power consumption (voltage*current) values of the two measurement sets shall be below ± 10 % of the average or ± 5 W, whichever value is larger. Then, the arithmetic average of the two averaged power values shall be taken.

• 3.3.8.7. If the deviation is higher, the set of averaged voltage and current values giving the largest averaged power consumption shall be taken, or the test shall be repeated for the gear.

3.3.9.   Measurement uncertainty

The part of the calculated total uncertainty UT,loss exceeding 5 % of Tloss or 1 Nm (ΔUT,loss), whichever value of ΔUT,loss is smaller, shall be added to Tloss for the reported torque loss Tloss,rep. If UT,loss is smaller than 5 % of Tloss or 1 Nm, then Tloss,rep = Tloss.

Tloss,rep = Tloss + MAX (0, ΔUT,loss)

ΔUT,loss = MIN ((UT,loss – 5 % * Tloss), (UT,loss – 1 Nm))

For each measurement set, the total uncertainty UT,loss of the torque loss shall be calculated based on the following parameters:

• (1) Temperature effect

• (2) Parasitic loads

• (3) Calibration error (incl. sensitivity tolerance, linearity, hysteresis and repeatability)

The total uncertainty of the torque loss (UT,loss) is based on the uncertainties of the sensors at 95 % confidence level. The calculation shall be done as the square root of the sum of squares (‘Gaussian law of error propagation’).

Image omitted; see official source

Image omitted; see official source

Image omitted; see official source

Image omitted; see official source

Image omitted; see official source

Image omitted; see official source

wpara = senspara * ipara

where:

Tloss	=	Measured torque loss (uncorrected) [Nm]
---	---	---
Tloss,rep	=	Reported torque loss (after uncertainty correction) [Nm]
---	---	---
UT,loss	=	Total expanded uncertainty of torque loss measurement at 95 % confidence level [Nm]
---	---	---
uT,in/out	=	Uncertainty of input/output torque loss measurement separately for input and output torque sensor[Nm]
---	---	---
igear	=	Gear ratio [-]
---	---	---
uTKC	=	Uncertainty by temperature influence on current torque signal [Nm]
---	---	---
wtkc	=	Temperature influence on current torque signal per Kref, declared by sensor manufacturer [%]
---	---	---
uTK0	=	Uncertainty by temperature influence on zero torque signal (related to nominal torque) [Nm]
---	---	---
wtk0	=	Temperature influence on zero torque signal per Kref (related to nominal torque), declared by sensor manufacturer [%]
---	---	---
Kref	=	Reference temperature span for uTKC and uTK0, wtk0 and wtkc, declared by sensor manufacturer [K]
---	---	---
ΔK	=	Difference in sensor temperature between calibration and measurement [K]. If the sensor temperature cannot be measured, a default value of ΔK = 15 K shall be used.
---	---	---
Tc	=	Current/measured torque value at torque sensor [Nm]
---	---	---
Tn	=	Nominal torque value of torque sensor [Nm]
---	---	---
ucal	=	Uncertainty by torque sensor calibration [Nm]
---	---	---
Wcal	=	Relative calibration uncertainty (related to nominal torque) [%]
---	---	---
kcal	=	calibration advancement factor (if declared by sensor manufacturer, otherwise = 1)
---	---	---
upara	=	Uncertainty by parasitic loads [Nm]
---	---	---
wpara	=	senspara * ipara Relative influence of forces and bending torques caused by misalignment [%]
---	---	---
senspara	=	Maximum influence of parasitic loads for specific torque sensor declared by sensor manufacturer [%]; if no specific value for parasitic loads is declared by the sensor manufacturer, the value shall be set to 1,0 %
---	---	---
ipara	=	Maximum influence of parasitic loads for specific torque sensor depending on test setup (A/B/C, as defined below).
---	---	---
	=	A) 10 % in case of bearings isolating the parasitic forces in front of and behind the sensor and a flexible coupling (or cardan shaft) installed functionally next to the sensor (downstream or upstream); furthermore, these bearings can be integrated in a driving/braking machine (e.g. electric machine) and/or in the transmission as long as the forces in the machine and/or transmission are isolated from the sensor. See figure 3. Figure 3 Example of test setup A for Option 3 Image omitted; see official source Text of image Test setup A OUTPUT INPUT E: Electric machine T: Torque sensor F: Flexible coupling B: Bearing TM: Transmission
---	---	---
	=	B) 50 % in case of bearings isolating the parasitic forces in front of and behind the sensor and no flexible coupling installed functionally next to the sensor; furthermore, these bearings can be integrated in a driving/braking machine (e.g. electric machine) and/or in the transmission as long as the forces in the machine and/or transmission are isolated from the sensor. See figure 4. Figure 4 Example of test setup B for Option 3 Image omitted; see official source Text of image Test setup B INPUT OUTPUT E: Electric machine T: Torque sensor B: Bearing TM: Transmission
---	---	---
	=	C) 100 % for other setups

A test set-up for the transmission with integrated differential for front-wheel drive operation consists of a dynamometer on the transmission input side and at least one dynamometer on the transmission output side(s). Torque measuring devices shall be installed on the transmission input and output side(s). For test setups with only one dynamometer on the output side, the free rotating end of the transmission with integrated differential shall be rotatably locked to the other end on the output side (e.g. by an activated differential lock or by means of any other mechanical differential lock implemented only for the measurement).

The graduation of the factor ipara for the maximum influence of parasitic loads for the specific torque sensors is equal to the cases described above (A/B/C).

Figure 5

Example of test setup A for a transmission with integrated differential (e.g. for front-wheel drive operation)

Image omitted; see official source

Figure 6

Example of test setup B for a transmission with integrated differential (e.g. for front-wheel drive operation)

Image omitted; see official source

In the case of a dynamometer on each output shaft, the total uncertainty of the torque loss (UT,loss) shall be calculated by:

Image omitted; see official source

The manufacturer may adapt the test setups A and B based upon good engineering judgement and in agreement with the approval authority, e.g. in the case of practical test setup reasons. In the case of such a deviation, the reason and alternative setup shall be clearly specified in the test report.

It is allowed to perform the test without a separate bearing unit on the test rig at the transmission input/output side, if the transmission shaft on which the torque is measured is supported by two bearings in the transmission housing which are able to absorb radial and axial forces caused by the gearsets (see figure 2C in 3.1.8.).

• 3.4. Complement of input files for the simulation tool

For each gear a torque loss map covering the defined input speed and input torque points shall be determined with one of the specified testing options or standard torque loss values. For the input file for the simulation tool, this basic torque loss map shall be complemented as described in the following:

• 3.4.1. In the cases the highest tested input speed was the last speed point below the defined maximum permissible transmission speed, an extrapolation of the torque loss shall be applied up to the maximum speed with linear regression based on the two last measured speed points.

• 3.4.2. In the cases the highest tested input torque was the last torque point below the defined maximum permissible transmission torque, an extrapolation of the torque loss shall be applied up to the maximum torque with linear regression based on the two last measured torque points for the corresponding speed point. In order to handle engine torque tolerances, etc., the simulation tool will, if required, perform an extrapolation of the torque loss for input torques up to 10 % above said defined maximum permissible transmission torque.

• 3.4.3. In the case of extrapolation of the torque loss values for maximum input speed and maximum input torque at the same time, the torque loss for the combined point of highest speed and highest torque shall be calculated with two-dimensional linear extrapolation.

• 3.4.4. If the maximum output torque exceeds 10 kNm (for a theoretical loss free transmission), and/or for all speed and torque points with input power higher than the specified maximum input power, the manufacturer may choose to take the torque loss values for all torques higher than 10 kNm, and/or for all speed and torque points with input power higher than the specified maximum input power, respectively, from one of:

• (1) Calculated fallback values (Appendix 8)

• (2) Option 1

- (3) Option 2 or 3 in combination with a torque sensor for higher output torques (if required)

For cases (i) and (ii) in Option 2, the torque losses at load shall be measured at the input torque that corresponds to output torque 10 kNm and/or the specified maximum input power.

• 3.4.5. For speeds below the defined minimum speed and the additional input speed step of 0 rpm, the reported torque losses determined for the minimum speed point shall be copied.

• 3.4.6. To cover the range of negative input torques during vehicle coasting conditions, the torque loss values for positive input torques shall be copied for the related negative input torques.

• 3.4.7. Upon agreement of an approval authority, the torque losses for the input speeds below 1 000 rpm may be replaced by the torque losses at 1 000 rpm when the measurement is technically not possible.

• 3.4.8. If the measurement of speed points is technically not possible (e.g. due to natural frequency), the manufacturer may, in agreement with the approval authority, calculate the torque losses by interpolation or extrapolation (limited to max. 1 speed point per gear).

• 3.4.9. The torque loss map data shall be formatted and saved as specified in Appendix 12 to this Annex.

The torque converter characteristics to be determined for the simulation tool input consist of T pum1000 (the reference torque at 1 000 rpm input speed) and μ (the torque ratio of the torque converter). Both are depending on the speed ratio v (= output (turbine) speed / input (pump) speed for the torque converter) of the torque converter.

For determination of the characteristics of the TC, the applicant for a certificate shall apply the following method, irrespective of the chosen option for the assessment of the transmission torque losses.

To take the two possible arrangements of the TC and the mechanical transmission parts into account, the following differentiation between case S and P shall apply:

Case S	:	TC and mechanical transmission parts in serial arrangement
---	---	---
Case P	:	TC and mechanical transmission parts in parallel arrangement (power split installation)

For case S arrangements the TC characteristics may be evaluated either separate from the mechanical transmission or in combination with the mechanical transmission. For case P arrangements the evaluation of TC characteristic is possible only in combination with the mechanical transmission. However, in this case and for the hydromechanical gears subject to measurement the whole arrangement, torque converter and mechanical transmission, is considered as a TC with similar characteristic curves as a sole torque converter. In the case of measurements together with a mechanical transmission, the speed ratio v and all corresponding values for step widths as well as limits shall be adjusted by taking the mechanical transmission ratio into account.

For the determination of the torque converter characteristics two measurement options may be applied:

• (i) Option A: measurement at constant input speed;

- (ii) Option B: measurement at constant input torque in accordance with SAE J643.

The manufacturer may choose option A or B for case S and case P arrangements.

For the input to the simulation tool, the torque ratio μ and reference torque Tpum of the torque converter shall be measured for a range of v ≤ 0,95 (= vehicle propulsion mode).

In the case of use of standard values, the data on torque converter characteristics provided to the simulation tool shall only cover the range of v ≤ 0,95 (or the adjusted speed ratio). The simulation tool automatically adds the generic values for overrun conditions.

Table 1

Default values for v ≥ 1,00

v	μ	Tpum 1000
1,000	1,0000	0,00
1,100	0,9999	– 40,34
1,222	0,9998	– 80,34
1,375	0,9997	– 136,11
1,571	0,9996	– 216,52
1,833	0,9995	– 335,19
2,200	0,9994	– 528,77
2,500	0,9993	– 721,00
3,000	0,9992	– 1 122,00
3,500	0,9991	– 1 648,00
4,000	0,9990	– 2 326,00
4,500	0,9989	– 3 182,00
5,000	0,9988	– 4 242,00

4.1.   Option A: Measured torque converter characteristics at constant speed

4.1.1.   General requirements

The torque converter used for the measurements shall be in accordance with the drawing specifications for series production torque converters.

Modifications to the TC to meet the testing requirements of this Annex, e.g. for the inclusion of measurement sensors are permitted.

Upon request of the approval authority the applicant for a certificate shall specify and prove the conformity with the requirements defined in this Annex.

4.1.2.   Oil temperature

The input oil temperature to the TC shall meet the following requirements:

The oil temperature for measurements of the TC separate from the transmission shall be 90 °C + 7/– 3 K.

The oil temperature for measurements of the TC together with the transmission (case S and case P) shall be 90 °C + 20/– 3 K.

The oil temperature shall be measured at the drain plug or in the oil sump.

In case the TC characteristics are measured separately form the transmission, the oil temperature shall be measured prior to entering the converter test drum/bench.

4.1.3.   Oil flow rate and pressure

The input TC oil flow rate and output oil pressure of the TC shall be kept within the specified operational limits for the torque converter, depending on the related transmission type and the tested maximum input speed.

4.1.4.   Oil quality/Oil viscosity

As specified for transmission testing in 3.1.2.5.3 and 3.1.2.5.4.

4.1.5.   Installation

The torque converter shall be installed on a testbed with a torque sensor, speed sensor and an electric machine installed at the input and output shaft of the TC.

4.1.6.   Measurement equipment

The calibration laboratory facilities shall comply with the requirements of either  IATF 16949, ISO 9000 series or ISO/IEC 17025. All laboratory reference measurement equipment, used for calibration and/or verification, shall be traceable to national (international) standards.

4.1.6.1.   Torque

The torque sensor measurement uncertainty shall be below 1 % of the measured torque value.

The use of torque sensors with higher measurement uncertainties is allowed if the part of the uncertainty exceeding 1 % of the measured torque can be calculated and is added to the measured torque loss as described in 4.1.7.

4.1.6.2.   Speed

The uncertainty of the speed sensors shall not exceed ± 1 rpm.

4.1.6.3.   Temperature

The uncertainty of the temperature sensors for the measurement of the ambient temperature shall not exceed ± 1,5 K.

The uncertainty of the temperature sensors for the measurement of the oil temperature shall not exceed ± 1,5 K.

4.1.7.   Test procedure

4.1.7.1.   Zero torque signal compensation

As specified in 3.1.6.1.

4.1.7.2.   Measurement sequence

• 4.1.7.2.1. The input speed npum of the TC shall be fixed to a constant speed within the range of:

1 000 rpm ≤ npum ≤ 2 000 rpm

• 4.1.7.2.2. The speed ratio v shall be adjusted by increasing the output speed ntur from 0 rpm up to the set value of npum.

• 4.1.7.2.3. The step width shall be 0,1 for the speed ratio range of 0 to 0,6 and 0,05 for the range of 0,6 to 0,95.

• 4.1.7.2.4. The upper limit of the speed ratio may be limited to a value below 0,95 by the manufacturer. In this case at least seven evenly distributed points between v = 0 and a value of v < 0,95 have to be covered by the measurement.

• 4.1.7.2.5. For each point a minimum of 3-second stabilisation time within the temperature limits defined in point 4.1.2. is required. If needed, the stabilization time may be extended by the manufacturer to maximum 60 seconds. The oil temperature shall be recorded during the stabilization.

• 4.1.7.2.6. For each point the signals specified in 4.1.8. shall be recorded for the test point for a minimum of 3 seconds but for no longer than 15 seconds.

• 4.1.7.2.7. The measurement sequence (4.1.7.2.1. to 4.1.7.2.6.) shall be performed two times in total.

4.1.8.   Measurement signals and data recording

At least the following signals shall be recorded during the measurement:

- (1) Input (pump) torque Tc,pum [Nm]

• (2) Output (turbine) torque Tc,tur [Nm]

• (3) Input rotational (pump) speed npum [rpm]

• (4) Output rotational (turbine) speed ntur [rpm]

• (5) TC input oil temperature KTCin [°C]

The sampling and recording rate shall be 100 Hz or higher.

A low pass filter shall be applied to avoid measurement errors.

4.1.9.   Measurement validation

• 4.1.9.1. The arithmetic mean values of torque and speed for the 03-15 seconds measurement shall be calculated for each of the two measurements.

- 4.1.9.2. The measured torques and speeds from the two sets shall be averaged (arithmetic mean values).

• 4.1.9.3. The deviation between the averaged torque of the two measurement sets shall be below ± 5 % of the average or ± 1 Nm (whichever value is larger). The arithmetic average of the two averaged torque values shall be taken. If the deviation is higher, the following value shall be taken for point 4.1.10. and 4.1.11. or the test shall be repeated for the TC.

• — for the calculation of ΔUT,pum/tur: smallest averaged torque value for Tc,pum/tur

• — for the calculation of torque ratio μ: largest averaged torque value for Tc,pum

• — for the calculation of torque ratio μ: smallest averaged torque value for Tc,tur

• — for the calculation of reference torque Tpum1000: smallest averaged torque value for Tc,pum

• 4.1.9.4. The measured and averaged speed and torque at the input shaft shall be below ± 5 rpm and ± 5 Nm of the speed and torque set point for each measured operating point for the complete speed ratio series.

4.1.10.   Measurement uncertainty

The part of the calculated measurement uncertainty UT,pum/tur exceeding 1 % of the measured torque Tc,pum/tur shall be used to correct the characteristic value of the TC as defined below.

ΔUT,pum/tur = MAX (0, (UT,pum/tur – 0,01 * Tc,pum/tur))

The uncertainty UT,pum/tur of the torque measurement shall be calculated based on the following parameter:

• (i) Calibration error (incl. sensitivity tolerance, linearity, hysteresis and repeatability)

The uncertainty UT,pum/tur of the torque measurement is based on the uncertainties of the sensors at 95 % confidence level.

UT,pum/tur = 2 * ucal

Image omitted; see official source

where:

| | | |

| --- | --- | --- | | Tc,pum/tur | = | Current / measured torque value at input/output torque sensor (uncorrected) [Nm] | | | | | | --- | --- | --- | | Tpum | = | Input (pump) torque (after uncertainty correction) [Nm] | | | | | | --- | --- | --- | | UT,pum/tur | = | Uncertainty of input / output torque measurement at 95 % confidence level separately for input and output torque sensor[Nm] | | | | | | --- | --- | --- | | Tn | = | Nominal torque value of torque sensor [Nm] | | | | | | --- | --- | --- | | ucal | = | Uncertainty by torque sensor calibration [Nm] | | | | | | --- | --- | --- | | Wcal | = | Relative calibration uncertainty (related to nominal torque) [%] | | | | | | --- | --- | --- | | kcal | = | Calibration advancement factor (if declared by sensor manufacturer, otherwise = 1) |

4.1.11.   Calculation of TC characteristics

For each measurement point, the following calculations shall be applied to the measurement data:

The torque ratio of the TC shall be calculated by

Image omitted; see official source

The speed ratio of the TC shall be calculated by

Image omitted; see official source

The reference torque at 1 000 rpm shall be calculated by

Image omitted; see official source

where:

| | | |

| --- | --- | --- | | μ | = | Torque ratio of the TC [-] | | | | | | --- | --- | --- | | v | = | Speed ratio of the TC [-] |

| | | |

| --- | --- | --- | | Tc,pum | = | Input (pump) torque (corrected) [Nm] | | | | | | --- | --- | --- | | npum | = | Input rotational (pump) speed [rpm] |

| | | |

| --- | --- | --- | | ntur | = | Output rotational (turbine) speed [rpm] | | | | | | --- | --- | --- | | Tpum1000 | = | Reference torque at 1 000 rpm [Nm] |

4.2.   Option B: Measurement at constant input torque (in accordance with SAE J643)

4.2.1.   General requirements

As specified in 4.1.1.

4.2.2.   Oil temperature

As specified in 4.1.2.

4.2.3.   Oil flow rate and pressure

As specified in 4.1.3.

4.2.4.   Oil quality

As specified in 4.1.4.

4.2.5.   Installation

As specified in 4.1.5.

4.2.6.   Measurement equipment

As specified in 4.1.6.

4.2.7.   Test procedure

4.2.7.1.   Zero torque signal compensation

As specified in 3.1.6.1.

4.2.7.2.   Measurement sequence

- 4.2.7.2.1. The input torque Tpum shall be set to a positive level at npum = 1 000 rpm with the output shaft of the TC held non-rotating (output speed ntur = 0 rpm).

• 4.2.7.2.2. The speed ratio v shall be adjusted by increasing the output speed ntur from 0 rpm up to a value of ntur covering the usable range of v with at least seven evenly distributed speed points.

- 4.2.7.2.3. The step width shall be 0.1 for the speed ratio range of 0 to 0,6 and 0,05 for the range of 0,6 to 0,95.

• 4.2.7.2.4. The upper limit of the speed ratio may be limited to a value below 0,95 by the manufacturer.

- 4.2.7.2.5. For each point a minimum of 5-second stabilisation time within the temperature limits defined in point 4.2.2. is required. If needed, the stabilization time may be extended by the manufacturer to maximum 60 seconds. The oil temperature shall be recorded during the stabilization.

• 4.2.7.2.6. For each point the values specified in 4.2.8. shall be recorded for the test point for a minimum of 5 seconds but for no longer than 15 seconds.

- 4.2.7.2.7. The measurement sequence (4.2.7.2.1. to 4.2.7.2.6.) shall be performed two times in total.

4.2.8.   Measurement signals and data recording

As specified in 4.1.8.

4.2.9.   Measurement validation

As specified in 4.1.9.

4.2.10.   Measurement uncertainty

As specified in 4.1.9.

4.2.11.   Calculation of TC characteristics

As specified in 4.1.11.

The scope of this section includes engine retarders, transmission retarders, driveline retarders, and components that are treated in the simulation tool as a retarder. These components include vehicle starting devices like a single wet transmission input clutch or hydro-dynamic clutch.

5.1.   Methods for establishing retarder drag losses

The retarder drag torque loss is a function of the retarder rotor speed. Since the retarder can be integrated in different parts of the vehicle driveline, the retarder rotor speed depends on the drive part (= speed reference) and step-up ratio between drive part and retarder rotor as shown in Table 2.

Table 2

Retarder rotor speeds

Configuration	Speed reference	Retarder rotor speed calculation
A. Engine Retarder	Engine Speed	nretarder = nengine * istep-up
B. Transmission Input Retarder	Transmission Input Shaft Speed	nretarder = ntransm.input * istep-up = ntransm.output * itransm * istep-up
C. Transmission Output Retarder or Axlegear Input Retarder	Transmission Output Shaft Speed or Axlegear Input Shaft Speed	nretarder = ntransm.output × istep-up

where:

| | | |

| --- | --- | --- | | istep-up | = | step-up ratio = retarder rotor speed/drive part speed | | | | | | --- | --- | --- | | itransm | = | transmission ratio = transmission input speed/transmission output speed |

Retarder configurations that are integrated in the engine and cannot be separated from the engine shall be tested in combination with the engine. This section does not cover these non-separable engine integrated retarders.

Retarders that can be disconnected from the driveline or the engine by any kind of clutch are considered to have zero rotor speed in disconnected condition and therefore have no power losses.

The retarder drag losses shall be measured with one of the following two methods:

• (1) Measurement on the retarder as a stand-alone unit

• (2) Measurement in combination with the transmission

5.1.1.   General requirements

In case the losses are measured on the retarder as stand-alone unit, the results are affected by the torque losses in the bearings of the test setup. It is permitted to measure these bearing losses and subtract them from the retarder drag loss measurements.

The manufacturer shall guarantee that the retarder used for the measurements is in accordance with the drawing specifications for series production retarders.

Modifications to the retarder to meet the testing requirements of this Annex, e.g. for the inclusion of measurement sensors or the adaption of an external oil conditioning systems are permitted.

Based on the family described in Appendix 6 to this Annex, measured drag losses for transmissions with retarder can be used for the same (equivalent) transmission without retarder.

The use of the same transmission unit for measuring the torque losses of variants with and without retarder is permitted.

Upon request of the approval authority the applicant for a certificate shall specify and prove the conformity with the requirements defined in this Annex.

5.1.2.   Run-in

On request of the applicant a run-in procedure may be applied to the retarder. The following provisions shall apply for a run-in procedure.

• 5.1.2.1 If the manufacturer applies a run-in procedure to the retarder, the run-in time for the retarder shall not exceed 100 hours at zero retarder apply torque. Optionally a share of a maximum of 6 hours with retarder apply torque may be included.

5.1.3.   Test conditions

5.1.3.1.   Ambient temperature

The ambient temperature during the test shall be in a range of 25 °C ± 10 K.

The ambient temperature shall be measured 1 m laterally from the retarder.

5.1.3.2.   Ambient pressure

For magnetic retarders the minimum ambient pressure shall be 899 hPa according to International Standard Atmosphere (ISA) ISO 2533.

5.1.3.3.   Oil or water temperature

For hydrodynamic retarders:

Except for the fluid, no external heating is allowed.

In case of testing as stand-alone unit, the retarder fluid temperature (oil or water) shall not exceed 87 °C.

In case of testing in combination with transmission, the oil temperature limits for transmission testing shall apply.

5.1.3.4.   Oil or water quality

New, recommended first fill oil for the European market shall be used in the test.

For water retarders the water quality shall meet the specifications set out by the manufacturer for the retarder. The water pressure shall be set to a fixed value close to vehicle condition (1 ± 0,2 bar relative pressure at retarder input hose).

5.1.3.5.   Oil viscosity

If several oils are recommended for first fill, they are considered to be equal if the oils have a kinematic viscosity within 50 % of each other at the same temperature (within the specified tolerance band for KV100).

5.1.3.6.   Oil or water level

The oil/water level shall meet the nominal specifications for the retarder.

5.1.4.   Installation

The electric machine, the torque sensor, and speed sensor shall be mounted at the input side of the retarder or transmission.

The installation of the retarder (and transmission) shall be done with an inclination angle as for installation in the vehicle according to the homologation drawing ± 1° or at 0° ± 1°.

5.1.5.   Measurement equipment

As specified for transmission testing in 3.1.4.

5.1.6.   Test procedure

5.1.6.1.   Zero torque signal compensation:

As specified for transmission testing in 3.1.6.1.

5.1.6.2.   Measurement sequence

The torque loss measurement sequence for the retarder testing shall follow the provisions for the transmission testing defined in 3.1.6.3.2. to 3.1.6.3.5.

5.1.6.2.1.   Measurement on the retarder as stand-alone unit

When the retarder is tested as stand-alone unit, torque loss measurements shall be conducted using the following speed points:

200, 400, 600, 900, 1 200 , 1 600 , 2 000 , 2 500 , 3 000 , 3 500 , 4 000 , 4 500 , 5 000 , continued up to the maximum retarder rotor speed.

5.1.6.2.2.   Measurement in combination with the transmission

- 5.1.6.2.2.1. In case the retarder is tested in combination with a transmission, the selected transmission gear shall allow the retarder to operate at its maximum rotor speed.

5.1.6.2.2.   The torque loss shall be measured at the operating speeds as indicated for the related transmission testing.

- 5.1.6.2.2.3. Measurement points may be added for transmission input speeds below 600 rpm if requested by the manufacturer.

• 5.1.6.2.2.4. The manufacturer may separate the retarder losses from the total transmission losses by testing in the order as described below:

- (1) The load-independent torque loss for the complete transmission including retarder shall be measured as defined in point 3.1. for transmission testing in one of the higher transmission gears:

= Tl,in,withret

• (2) The retarder and related parts shall be replaced with parts required for the equivalent transmission variant without retarder. The measurement of point (1) shall be repeated. = Tl,in,withoutret

• (3) The load-independent torque loss for the retarder system shall be determined by calculating the differences between the two test data sets = Tl,in,retsys = Tl,in,withret – Tl,in,withoutret

5.1.7.   Measurement signals and data recording

As specified for transmission testing in 3.1.5.

5.1.8.   Measurement validation

All recorded data shall be checked and processed as defined for transmission testing in 3.1.7.

5.2.   Complement of input files for the simulation tool

• 5.2.1 Retarder torque losses for speeds below the lowest measurement speed shall be set equal to the measured torque loss at this lowest measurement speed.

• 5.2.2 In case the retarder losses were separated out from the total losses by calculating the difference in data sets of testing with and without a retarder (see 5.1.6.2.2.4.), the actual retarder rotor speeds depend on the retarder location, and/or selected gear ratio and retarder step-up ratio and thereby may differ from the measured transmission input shaft speeds. The actual retarder rotor speeds relative to the measured drag loss data shall be calculated as described in 5.1. Table 2.

• 5.2.3 The torque loss map data shall be formatted and saved as specified in Appendix 12 to this Annex.

• 6.1.Methods for establishing losses of a drivetrain component with a single speed ratio

• The losses of a drivetrain component with a single speed ratio shall be determined using one of the following cases:

• 6.1.1.Case A: Measurement on a separate drivetrain component with a single speed ratio

• For the torque loss measurement of a drivetrain component with a single speed ratio, the three options as defined for the determination of the transmission losses shall apply:

Option 1	:	Measured torque independent losses and calculated torque dependent losses (Transmission test option 1)
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Option 2	:	Measured torque independent losses and measured torque dependent losses at full load (Transmission test option 2)
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Option 3	:	Measurement under full load points (Transmission test option 3)

• The measurement, the validation and the uncertainty calculation of the losses of a drivetrain component with a single speed ratio shall follow the procedure described for the related transmission test option in point 3 diverging in the following requirements:

• Measurements shall be performed at 200 rpm and 400 rpm (at the input shaft of the drivetrain component with a single speed ratio) and for the following speed points: 600, 900, 1 200 , 1 600 , 2 000 , 2 500 , 3 000 , 4 000 rpm and multiples of 10 of these values up to the maximum speed in accordance with specifications of the drivetrain component with a single speed ratio, or the last speed point before the defined maximum speed. It is permitted to measure additional intermediate speed points.

• 6.1.1.1Applicable speed range:

• 6.1.2.Case B: Individual measurement of a drivetrain component with a single speed ratio connected to a transmission

• Where the drivetrain component with a single speed ratio is tested in combination with a transmission, the testing shall follow one of the defined options for transmission testing:

Option 1	:	Measured torque independent losses and calculated torque dependent losses (Transmission test option 1)
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Option 2	:	Measured torque independent losses and measured torque dependent losses at full load (Transmission test option 2)
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Option 3	:	Measurement under full load points (Transmission test option 3)

• 6.1.2.1The manufacturer may separate the losses of a drivetrain component with a single speed ratio from the total transmission losses by testing in the order as described below:

• (1) The torque loss for the complete transmission including drivetrain component with a single speed ratio shall be measured as defined for the applicable transmission testing option = Tl,in,withad

• (2) The drivetrain component with a single speed ratio and related parts shall be replaced with parts required for the equivalent transmission variant without drivetrain component with a single speed ratio. The measurement of point (1) shall be repeated. = Tl,in,withoutad