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Brake Hose for Motor Vehicles-Implementation Rules for Compulsory Certification of Motor Vehicle Products
No. CNCA-02C-057: 2005
Brake Hose for Motor Vehicles
Implementation Rules for Compulsory Certification of Motor Vehicle Products
Issued on Oct 10th 20005 Effective on Dec 1st 2005
Issued by the Certification and Accreditation Administration of PRC
1. Scope
This rule applies to hydraulic pressure, air pressure and vacuum brake hose assemblies used by vehicles ,trailers, motorcycles and mopeds.
2. Certification mode
Type test + initial factory inspection + supervision after inspection
Note: For the convenience of client, the certification mode also can be: Initial Factory Inspection +Type Test + Supervision after Inspection. (Under the special situation, the client for the commission can send the sample to the certification body for the test).
3. Basic procedure of the certification
3.1 Commission and acceptance of the certification
3.2 Type tests
3.3 Initial factory inspection
3.4 Evaluation of certification results and approval of certification
3.5 Supervision after inspection
4.Basic requirements of the certification
4.1 Commission and acceptance of the certification
4.1.1 Principle for unit classification
In principle, the hydraulic, barometric and vacuum brake hose assemblies without jacket for vehicles trailers motorcycles and mopeds made by the same factory, and having no difference in the following aspects could be classified as one certification unit:
1) The way for the brake transmission (hydraulic, air and vacuum)
2) Hose materials
3) The connection way of the end and the hose
4.1.2 Documents and Materials Needed for Certification can refer to Appendix 1.
4.2 Type tests
4.2.1 Sampling for type tests
4.2.1.1 Principles for sampling
As for one unit to be certified, if there is only one type of products, this type should be sampled.
As for one unit to be certified, if there is more than one type of products, the representative sample should be selected by the certification body. Once needed, the other types should be sampled to conduct the discrepancy tests.
4.2.1.2 Time to sample
Normally, sampling should be conducted before initial factory inspection. It also can be conducted simultaneously with initial factory inspection for the convenience of applicants.
4.2.1.3 Methods for sampling
The samples should be selected at random from the qualified products of the factory, including products on production line and in warehouse. The sampling base should not be lower than ten times of the amount of the samples.
The samples should be sealed and then sent to the appointed organization for test.
4.2.1.4 Amount of samples:
Hydraulic brake hose assemblies: 35
Air brake hose assemblies: 28
Vacuum brake hose assemblies: 17
If products in the same unit have the different inside diameters, the number of samples with different diameter should be added in order to conduct the difference-test.
Hydraulic brake hose assemblies: 16
Air brake hose assemblies: 9
Vacuum brake hose assemblies: 10
If products in the same unit have the different ends, the number of samples with different diameter should be added in order to conduct the difference-test.
Hydraulic brake hose assemblies: 9
Air brake hose assemblies: 7
Vacuum brake hose assemblies: 3
4.2.1.5 Disposal of the samples used for type tests and the relevant documents
After the test, certificated samples and relevant materials must be disposed in a suitable way.
4.2.2 Test standards, bases and items
For the test items and test specifications, please refer to Appendix 2.
4.3 Initial factory inspection
4.3.1 Time for initial factory inspection
Generally speaking, once the products have passed type tests, initial factory inspection can be conducted.
The time for initial factory inspection will be decided according to the application units and the amounts of products covered by the models, and as well the considerations should be given to the production scale of the factories. Usually each factory will need 2 to 6 person/days.
4.3.2 Inspection contents
It covers the inspections on the quality assurance abilities of the factory and the inspections on its’ product consistency.
4.3.2.1 Inspections on the quality assurance abilities of the factory
The Requirements on the Quality Assurance Abilities of the Factories for Compulsory Certification (refer to Appendix 3) are the basic requirements used in initial factory inspection on quality assurance abilities for products covered in this rule.
4.3.2.2 Inspection on product consistency
During the factory inspection, the consistency of the certified products must be checked, which includes:
1) The markings of the certified products (such as name, specification, model and trademark etc) should be consistent with those stated in the documents submitted for the commission and acceptance;
2) The structures of certified products should be consistent with those of samples and those stated in documents submitted for the commission and acceptance;
3) The key components of certified products should be consistent with those of samples and those states in documents submitted for the commission and acceptance;
4) The designated on-site tests: the test items should be selected from the routine tests or verification tests (refer to the Appendix 3);
If there will be any problem in the inspection on product consistency, the certified body should give the measures for reform and consolidation、re-type test or breaking down this certification according to the situation.
4.3.3The inspections on the quality assurance abilities of factory should cover the processing workshops that produce the certified products, and the inspections on product consistency should cover the certified products.
4.4 Evaluation of certification results and approval of certification
4.4.1 Evaluation of certification results and approval of certification
Certification body will make a comprehensive evaluation to the type tests and factory inspection results. With the approval of the certification body, the certificate will be granted to the applicant (one certificate for one unit). The usage of the certificate should meet the requirements specified by the 《Administration Rule for Compulsory Certification》.
If the type tests of the certified products can not meet the requirements, a deadline (not more than 3 months) will be given for making the improvements, if the improvement can be finished timely, the re-tests can be applied; as for the disqualified factory inspection, a deadline (not more than 3 months) will be given for making the improvements, the certification body will confirm the results in a suitable way. As for those products that have passed re-examinations of the type tests and factory inspection, the certificate will be granted after the certification body has confirmed the results; as for the products that could not be improved within the time limit or that are still disqualified after the improvements are made, this certification will be terminated.
4.4.2 Time limit for the certification
The time for certification is calculated from the date when the commission of the certification is accepted to the date when the certificate is issued, including the time for type tests, factory inspection, evaluation and approval of the certification results, and the time for preparing the certificate.
The time for type tests will not exceed 20 working days, which is calculated from the date when samples are delivered to the designated test institution.
Normally, there are 5 working days for providing the Inspection Report. It should be calculated from the date when the inspector finishes the inspection and receives the report for the corrective action regarding the disqualification from the manufacturer.
There will be not more than 5 working days for evaluating & approving the certification results and preparing the certificate.
4.5 Supervision after inspection
4.5.1 Frequency of the supervision
4.5.1.1 Generally speaking, the first supervision will be made 6 months after the certificate granted. Afterwards, there will be at least one inspection half a year.
4.5.1.2 There will be a decrease of frequency for the inspection when any one of the following situations occurs, but at least once a year.
1) Supplying the complete vehicle manufacturer, and the complete vehicle manufacturer is qualified to the second party evaluation; furthermore there is no safety problem of the certified products in the last two years, and as well there are no non-consistency problem during all the follow-up inspections.
2) When the certified products have no safety and quality problems in the last two years; and as well there are no non-consistency problems during all the follow-up inspections; no problems appear during the mandatory inspection for certification and the national supervision inspection by sampling; and furthermore the certification body has enough reasons to judge the certified products satisfying the requirements.
4.5.1.3 There will be an increase of the frequency for the inspection when any one of the following situation occurs.
1) Serious quality problems in the certificated products occurs, or the responsibilities of the certificate holder are confirmed after the consumer complains.
2) The certification body has enough reasons to question the consistency between the certificated products and the requirements specified by this rule.
3) There is enough information showing that the compliance and consistency of the certified products may be influenced by the changes in terms of the organization, the working condition as well as quality assurance system in the manufacturer.
4.5.2 Content of the supervision
The supervision mode after granting the certificate should include: rechecking of the quality assurance abilities of the factory+ checking the consistency of the certificated product + random samples tests, (at least one time per year).
For the convenient of the applicant, the test results of sampling also can be considered as the result of the verification test.
4.5.2.1 Rechecking of the quality assurance abilities of the factory
It is the certification body to conduct the rechecks of the factory according to the Requirements on the Quality Assurance Abilities of the Factories for Compulsory Certification.
Items 3, 4, 5, 9, which specified in the Requirements on the Quality Assurance Abilities of the Factories for Compulsory Certification must be checked for every supervision, the other items can be checked selectively.
Every four years, all the items must be covered.
Normally, the supervision will take 1 to 2 man-day for each factory.
4.5.2.2 Checking of the consistency of the certificated products
During the supervision, the on-site consistency inspection to the certified products should be conducted. Refer to the item 4.3.2.2 for detailed inspection.
4.5.3 The evaluation of the supervision results after granting the certificate
After the evaluation by the certification body, the certificate qualification and certificate marks can be retained continuously for the satisfactory results. If there is any disqualification on the product itself, the certificate will be withdrawn according to the situation, and the usage of the marks will be stopped, and the notification of such withdrawal will be made public. For those that disqualified on the quality assurance abilities, the correction actions should be taken and finished within three months. Otherwise, the certificate and marks will be withdrawn and stopped, and the notification of such withdrawal will be made public.
5. Certificate
5.1 Validity of the certificate
The certificate of the products covered by this rule will not stipulate the deadline of the validity in principle. The validity of the certificate depends on the regular supervision of the certification body.
5.2 Modifications of the certificate
For the certificate of the products covered by this rule, if any of the following changes occurs, an application for the modifications should be submitted to the certification body:
1) Increase/decrease the certified products of the same unit
2) There is any change on the key parts/components, raw materials, structure, manufacturing process and suppliers of the certified products.
3) There is any change of the certified products on the trademark, applicant, manufacturer or factory information (names and/or address, quality assurance system).
4) Other changes that might influence the certification requirements.
The certification body should review and confirm the above changes and confirm the validity of the original certification results to the changes. If necessary, it should conduct the additional tests or inspections on the quality assurance system of the factory, and confirm that the original certificate remains in validity and/or re-issue a new certificate.
5.3 Suspension, cancellation and withdrawal of the certificate
The suspension, cancellation and withdrawal of the certificate should be implemented in accordance with the Administration Rule for the Product Compulsory Certification. During the suspension period and after the cancellation and withdrawal, the products should not be delivered out of the factory or imported.
6. Usage of the compulsory certification marks
The holder of the certificate should obey the relevant requirements of the Administration Rule for the Product Compulsory Certification Markings.
6.1 Mark design allowed to be used
6.2 Application and positions of mark
The certification symbol mark should be put on the outside surfaces of the hose, the manufacture code must be printed on a suitable place around the mark. The usage of the mark should be submitted to the CNCA authorized administration department for CCC marking for review and approval.
7. Charge
The CCC charge should include the fees for application, product tests, factory inspection, approval and registration (including the fees for the certificate), and the fees for the supervisions and re-checks, annuity and certificate marks, etc. It is the Certificate Body that imposing the charge according to the relevant government regulations.
Appendix 1
Documents required to be submitted for commission of the certification 1. Description of product (the following contents at least must be included)
1.1 Name and model
1.2 the way for the brake transmission (hydraulic, air and vacuum)
1.3 the nominal inside diameter
1.4 hose materials
1.5 hose ends
1.6 the connection way of the end and the hose
1.7 Other things need to explain
2. The photos that is enough to recognize the main characteristics of the products
3.Necessary drawings/illustrated instructions of the product structure
4.List of key parts/components and key materials
4.1 key parts covered by this rule: the hose, ends and hose materials (framework, rubber, nylon and so on)
4.2 The list should include at least the names, models, specifications, inspection items and suppliers of the key parts & components and key materials.
5.Brief introduction of the factory
5.1 Production introduction (the production scale, production capability and production history of the products that want to apply the certification.).
5.2 List of the key production facilities
5.3 List of the key inspection or testing instruments (including the names, models, specifications, quantities, accuracies, calibration periods and so on).
5.4 File catalogue of the quality management system related to attachment 3, organization block diagram/chart, and the documents for specifying the responsibilities.
6.Necessary test reports for the products to be certified
7.Registration papers of the applicant or factory
8.Other documents requested by the certification body
Appendix 2
Test items and test bases
1.Test standard GB 16897-1997 Brake Hose
2.Test items No. Test items Standard items
1 Hydraulic pressure brake hose
1-1 Appearance and labeling 8
1-2 Throughput of the bore after constriction 5.2.1
1-3 The maximum expansion 5.2.2
1-4 Burst intensity 5.2.3
1-5 Compatibility of the brake fluid 5.2.4
1-6 Flexibility fatigue 5.2.5
1-7 Tensile intensity 5.2.6
1-8 Water absorption 5.2.7
1-9 Low temperature resistance 5.2.8
1-10 Ozone resistance 5.2.9
1-11 Corrosion resistance of the fittings 5.2.10
2 Air brake hose
2-1 Appearance and labeling 8
2-2 Throughput of the bore after constriction 6.2.1
2-3 Air seal test 6.2.2
2-4 Length change rate (except for the hoses twisted by nylon) 6.2.3
2-5 Burst intensity 6.2.4
2-6 Tensile intensity 6.2.5
2-7 Adherence intensity (only for the rubber hose) 6.2.6
2-8 High temperature resistance 6.2.7
2-9 Low temperature resistance 6.2.8
2-10 Oil resistance 6.2.9
2-11 Tensile intensity after the water absorption 6.2.10
2-12 Ozone resistance 6.2.11
2-13 Zinc Chloride resistance of the nylon hose 6.2.12
2-14 Corrosion resistance of the fittings 6.2.13
3 Vacuum brake hose
3-1 Appearance and labeling 8
3-2 Throughput of the bore after constriction 7.1.1
3-3 Vacuum 7.1.2
3-4 Burst intensity 7.1.3
3-5 Bending test 7.1.4
3-6 Adherence intensity (only for the rubber hose) 7.1.5
3-7 High temperature resistance 7.1.6
3-8 Low temperature resistance 7.1.7
3-9 Ozone resistance 7.1.8
3-10 Gasoline resistance 7.1.9
3-11 Deformation requirement 7.1.10
3-12 Corrosion resistance of the fittings 7.1.11
Note
1. If the hoses in the same unit have the different diameters, the difference-test of the hose corresponding each diameter should be added according to article 5.2.1,5.2.2,5.2.3,5.2.5,5.2.6;6.2.1,6.2.4,6.2.5,6.2.7;7.1.1,7.1.3,7.1.4,7.1.6,7.1.7,7.1.10 and 7.1.11.
2. If the hose ends in the same unit are different, the difference-test of the hose corresponding each diameter should be added according to article 5.2.1,5.2.3,5.2.6,5.2.10;6.2.1,6.2.4,6.2.5,6.2.13;7.1.1,7.1.3 and 7.1.11.
Note: The standards should adopt the presently valid edition. Appendix 3
Requirements on the quality assurance capabilities of the factories for CCC certification Factory shall meet the requirements for factory’s quality assurance capability specified in this rule, in order to ensure that all certified products are identical with the samples which have passed the type test.
1. Responsibility and Resource
1.1 Responsibility
Factory shall define the responsibilities and inter-relations of all the personnel involved in the quality activities. And factory should appoint a management representative for quality, who, irrespective of other responsibilities, shall be responsible for:
a) Ensuring that quality system, which meets the requirements of this document is established, implemented and maintained.
b) Ensuring that the products with the compulsory certification mark are produced in conformity with the standards according to which they have been certified.
c) Establishing documented procedures to ensure that Compulsory certification marks are kept and used appropriately.
d) Establishing documented procedures to ensure that the compulsory certification mark is not affixed on any non-conforming product or changed product that was not notified to the certification body.
The management representative for quality shall be competent to perform the work.
Personnel shall be appointed to supervise the production operations across all shifts in order to ensure the product quality.
Personnel responsible for product quality shall have the authority to stop production in order to correct quality problems.
1.2 Resource
Factory shall be equipped with necessary production facilities and testing equipments in order to manufacture products consistently in conformity with relevant standards. In addition, factory shall provide relevant human resources, to ensure that personnel performing work affecting product quality is competent, and shall establish and maintain necessary environment suitable for manufacturing, testing and inspection, storage etc.
2.Documents and Records
2.1 Factory shall establish and maintain documented quality plan or relevant documents for certified products, and the documents needed to ensure that both the operation and control of these processes are effective. Quality plan shall define the objective of product design, realization process, inspection and related resource, as well as the requirements for modification (i.e. specification, processing, critical components etc.) to certified products, the use and management of marks.
Standard or specification that the design is based on, as one essential part of quality plan, shall be stricter than the requirements specified in this rules.
2.2 Factory shall establish and maintain documented procedure to control the documents required in this rule, to ensure that::
a) Authorized personnel shall approve all documents issued and changed prior to issue and change.
b) Changes and current revision status of documents are identified to prevent unexpected use of obsolete documents.
c) Relevant valid versions of applicable documents are available at points of use.
2.3 Factory shall establish and maintain documented procedures to define the controls for the identification, storage, protection and disposition of quality records. Records shall be legible, integral to provide evidence of product conformity to requirements.
Records shall be retained for an appropriate period.
3.Purchasing and receiving Inspection
3.1 Control of supplier
Factory shall establish the procedures that define the criteria for selection, evaluation and routine supervision of supplier, which provide critical components and material, and requirements for certification of product and processes, to ensure the supplier has capability to provide the critical components and material in accordance with requirements.
Records of the evaluations and routine supervision shall be maintained.
3.2 Inspection/Verification for Critical Components and Material
Factory shall establish and maintain procedures of inspection or verification for purchased critical components and material, and procedure of periodic verification inspection, to ensure that critical components and material meet the specified certification requirements. Procedures should include test item, test method, frequency and evaluation criteria.
Inspection for critical components and materials can be carried out by the manufacturer or the suppliers. Where inspection performed by the suppliers, the manufacturer shall specify the intended inspection requirements to suppliers.
Factory shall maintain the records of inspection or verification of critical components, verification inspection records, evidence of conformity and relevant inspection data, etc.
4.Production Processes Control and Inspection
4.1 Processes Preparation
4.1.1 Factory shall identify and validation critical production processes. The operators for the critical production processes should have the appropriate qualification. If the product quality cannot be guaranteed without operating documents, appropriate operating instructions shall be prepared to make production processes under control.
4.1.2 Study the key production processes to verify processes capability and provide input for process control.
4.1.3 Verification of the production preparation should be conducted in a suitable manner.
4.2 Where environment condition is required, factory shall meet the requirements.
4.3 Factory shall monitor and control the appropriate process parameters and product characteristics, as applicable.
4.4 Factory shall establish and implement the systems for production tooling management and for key production equipment preventive maintenance.
4.5 Production shall be inspected at appropriate stages of production to ensure that products, components and parts are in accordance with the sample that approved by the certificate.
4.6 Factory shall establish and implement a system for production tracecapability. Where appropriate, factory should determine and use the statistic technology.
5.Routine Tests and Verification Tests
Factory shall establish and maintain documented routine tests and verification tests procedures to verify and demonstrate that products are in compliance with relevant requirements. The procedures shall include test items, contents, method, acceptance criteria etc. Test records shall be maintained. The specific routine tests and verification tests should meet the related requirements of the product certification and implementation rules.
Routine tests are performed on 100% of production and are normally carried out at the final stage of production. Normally no further operations, except for labeling and packing, may be carried out after these tests.
Those are the routine test items of brake hose:
No Test items Standard items
1 Appearance Article 8 in GB 16897
2 Throughput of the bore after constriction Article 5.2.1, 6.2.1, 7.1.1 in GB 16897
3 Air seal test (Air brake hose) Article 6.2.2 in GB 16897 Verification tests are tests on samples taken randomly in order to verify and demonstrate that products meet standard requirements consistently.
The verification test items of brake hose should cover all the items in the Appendix 2. The minimum frequency of every unit for the verification test items should be 1 time per year.
6. Inspection and Test Equipments
The equipment used for inspection and test must be regularly calibrated and checked for correct operation, and meet inspection and test capacity requirements.
Factory should stipulate the operation rules for the inspection and test equipment. Testing personnel should follow the rules and use the equipment correctly.
6.1 Calibration and verification
Inspection and test equipment used for determining the conformity of the products being manufactured shall be calibrated or verified at a specified interval. All calibrations or verifications undertaken on such equipments must be traceable to national or international standards. For in-house calibration, the method, acceptance criteria, calibration interval etc. shall be regulated. Calibration or verification status of the equipment shall be easily identified by operator and personnel in-charge.
Calibration or verification records shall be maintained appropriately.
6.2 Measurement system analysis
Measurement system analysis shall be conducted by factory to analyze and measure the variation present in the result of each type of measuring and test equipment system. Where appropriate, the repeatability and reappearability (R&R) of the measurement system and sample product can be used to do the analysis.
6.3 Laboratory management
A factory’s internal laboratory facility shall have a defined scope that includes its capability to perform the required inspection, test or calibration services.
External/commercial independent laboratory facilities used for inspection, test or calibration services shall have a defined scope that includes the capability to perform the required inspection, test or calibration.
7.Control of Non-conforming Product
Factory shall establish control procedure of the non-conforming product, which shall include identification method, segregation, disposal, corrective action and preventive action.
Factory shall establish procedure instructions for rework and re-repair, including that the repaired and reworked product shall be re-tested. The repairing for important components and parts shall be recorded.
Product with unidentified or suspect status shall be classified as nonconforming product.
Useless product must be controlled by the similar method to non-conforming product.
Disposal record of the non-conformity product shall be maintained.
8. Internal Audit
Internal audit procedures shall be established and documented to ensure that validity of the quality system and the consistency of the certified products. The results of internal audit shall be maintained.
Factory shall keep records of all complaints, especially to a product which not compliance with the requirements of relevant standard, and make these complaints as the inputs of the internal audit.
The factory shall conduct internal audits at appropriate interval to determine whether the quality management system is effective.
The factory shall audit product at appropriate interval and stage of production to verify compliance to all specified requirements.
Corrective and preventive actions shall be taken and recorded shall be maintained.
9.Consistency of Certified Product
Manufacture should control the consistency between the mass-production products and the products having passed type tests so as to ensure the permanent conformity of the certificated products to relevant standards.
Factory shall establish the modification control procedures to the key component, material, construction and factors that may affect product compliance with the relevant standards. The modification of the certified products (which may affect the conformity with relevant standard or original sample for type testing consistently) must be notified to the certification body for authorization, prior to their implementation.
10. Packing, carrying and Storage
Packing, carrying and storage surrounding should not affect the products’ consistency to the relevant standards.
In order to detect deterioration, the condition of product in storage shall be assessed at appropriate planned intervals.
Notes: contents in italics are quoted from GB/T18305-2003.
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