wdk guideline for examination

of tyre technology

Test guideline for tyre changers

Version 1.0

February 2008
Contents:

Introduction ................................................................................................................ 3

1. Description of the guideline .................................................................................... 4

2. Quality requirements to tyre changers ................................................................... 5

3. Description of the test ............................................................................................ 5

4. Test procedure and documentation........................................................................ 6

4.1 Test procedure

4.2 Documentation

5. Mounting test of UHP/run-flat tyres - Data record and evaluation .......................... 8

6. Rims..................................................................................................................... 10

7. Tyres .................................................................................................................... 10

8. Documentation ..................................................................................................... 10

Appendix .................................................................................................................. 13

2
Introduction
During the mounting and demounting process of UHP and run-flat tyres with different
rims and tyre changers used in the market, in the worst case damage to the bead and
inner liner area of the tyre can occur.

Such damage can be linked to the following combinations:

• Tyre brand
• Rim type
• Type of tyre changer and related accessories
• Choice of accessories (e.g. lubricant)
• Knowledge and competence of the staff

The tyre changers and their related special accessories have a major influence on trou-
ble-free mounting of UHP and run-flat tyres.

Basis of the test guideline for tyre changers is the wdk guideline "Mounting/Demounting
Instructions for UHP and Run-flat Tyres", which was elaborated by the German Rubber
Association (wdk) in co-operation with manufacturers of cars, tyres, rims and tyre
changers as well as the German Association of Tyre Trade (BRV) and testing institutes
(DEKRA, MPA Darmstadt).

3
1. Description of the guideline

This guideline covers the requirements of machines and systems, which ensure a safe
mounting and demounting of UHP tyres and RFT. It forms the basis for certification of
machines.

Implementation and test criteria are defined to allow

• error and damage-free mounting and demounting of UHP tyres and RFT,
• as well as the documentation and the proof of the mounting and demounting of
UHP tyres and RFT.

The tyre changer supplied by the customer is tested to ensure the error-free mounting of
UHP tyres and RFT. Furthermore, the manufacturer of the tyre changer will provide all
necessary information (i.e. handbooks) for the mounting and demounting operations.

The tyre changer and the accessories supplied by the customer are evaluated for com-
pliance with state-of-the-art mounting techniques.

With this guideline the implementation conditions of the processes are defined, which
consist of specifications and requirements defined by customers and contractors.

The results are to be processed such that each test step can be understood to allow, if
necessary, appropriate improvement by the manufacturer (documentation of deficien-
cies).

The mounting tests of UHP tyres and RFT can result in technical insights which can lead
to technical improvements. However, these are not constituent and primary goal of the
examinations to be conducted.

The mounting of UHP tyres and RFT within the scope of the certification measures is car-
ried out according to the following criteria:

• mounting according to wdk instructions "Mounting and demounting instructions

of UHP and run-flat tyres"
• according to the user manual of the machine manufacturer
• using accessories provided by the machine manufacturer - standard, UHP and
run-flat tyres
• using a lubricant (correctly specified) suitable for UHP and RFT
• UHP tyres and RFT chosen by authorized persons.

A certificate will be issued if the tyre changer has fulfilled all requirements for error-free
mounting and demounting of UHP tyres and RFT.

4
2. Quality requirements to tyre changers

The tyre changers must comply with the legal requirements of those countries in which
they are used as well as the conditions and requirements of the Employers' Liability In-
surance Association (Germany) or other supervisory authorities and institutions.

1. Concerning the requirements to tyre changers the manufacturer has to guarantee

and to ensure that the mounting and demounting process can be always accom-
plished in constant quality and efficiency.
2. The wdk guideline for the mounting of UHP tyres and RFT is part of the manual of
the manufacturer and of the test criteria as well.
3. The manufacturer must designate in his manual all parts that have to be used to
ensure error-free mounting and demounting of UHP tyres and RFT.
4. The manufacturer describes in his manual all steps required for error-free mount-
ing and demounting.
5. It must be ensured that the machine operates wear-free. Otherwise wear parts
must be specified and replacement criteria or replacement intervals must be ad-
vised to the user.
6. In case the tyre changer or parts of the machine must be readjusted or be re-
placed after a certain period of time/use, the user must be informed accordingly.
7. In case improvements regarding the optimization of mounting and demounting of
UHP tyres and RFT are available, the manufacturer should inform the user without
delay.

The above mentioned criteria are prerequisites to ensure a constant level of quality dur-
ing the mounting and demounting processes.

3. Description of the test

The mounting tests will be carried out according to a
• defined
and
• reproducible sequence of operations.

The following accessories are also to be tested:

• Tyre levers
• Hold-downs
• Bead clamps
• Holding devices
• Mechanical, hydraulic or pneumatic devices for retaining and/or locking tyres
(must not damage nor compress the tyre bead, the belt edge and the tyre).

The machine manufacturer defines the operational condition of the machine that includes
all required accessories and mounting instructions of the manufacturer.

5
The mounting and demounting test documents include the following items:
• Features
• Errors
• Illustration of damage
• Mounting forces.

4. Test procedure and documentation

4.1 Test procedure

The standard procedure for mounting and demounting of tyres is carried out according to
the operational procedure defined in the wdk mounting/demounting instructions.

Furthermore the mounting and demounting tests are carried out according to the follow-
ing definitions:

• The DOT side with the date code is specified as side 1

• The DOT side without the date code is specified as side 2
• The DOT date position is always specified as position 12 o'clock
• The DOT mark is usually placed at the valve

Each tyre in the test series is mounted and dismounted twice each according to the fol-
lowing steps:

Part A

Mounting and demounting of both tyre beads. Bead of side 1 is mounted as second
bead.
• Mount the tyres such that side 1 will be positioned on the outer side of the
bead seat on the rim.
• Inflate the tyres
• Demount or push down the tyre beads from the bead seats
• During the mounting process record the forces of the bead exerted in direction
of the rim using a measuring rim
• Demount the tyre; during this process record the forces of the tyre lever ex-
erted in the direction of the rim.

Immediately after demounting of the tyre bead, side 1 will be cleaned, checked and the
results are recorded.

Part B

Mounting of both tyre beads; the bead of side 2 is mounted as the second bead.

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 • Mount the tyres such that side 2 will be positioned on the outer side of the
bead seat of the rim
• Inflate the tyres
• Demount or push down the tyre beads from the bead seats
• During the mounting process record the forces of the bead exerted in direction
of the rim using a measuring rim
• Demount the tyre; during this process record the forces of the tyre lever ex-
erted in the direction of the rim.

Immediately after demounting of the tyre bead, side 2 will be cleaned, checked and the
results are recorded.

4.2 Evaluation

The evaluation of the machine is carried out according to the procedure described in the
wdk mounting/demounting instructions and according to the test criteria (Appendix 2).

All observations will be classified as follows:

A error-free process sequence (no failures in mounting process or on tyres)

B1 critical process sequence (machine cannot be released without improvement
of certain aspects)
B2 safety-relevant damages (machine or process cycle must be revised in prin-
ciple)

The tyre evaluation is carried out according to the following scheme in regards to the
attributes from the criteria catalog:

1 = no failure and damage

small or light mark of DM or TP
2 = clearly visible mark or minor failure
no crack or rubber damage

3 = deep mark or failure with rubber damage

crack or cut not reaching down to the ply;
tyres with bead cover layer: visible structure without cracks
risk of leakage
4 = damaged by small cracks in rubber or cuts in the bead toe,
cover ply slightly torn
risk of leakage which might become detrimental to car safety

5 = essential damage by cracks, cuts or injuries down to the ply turn-up / bead
core rubber
6 = damage - detrimental to car safety - by cracks, cuts or injuries to the ply turn-
up, rubber damage, visible bead core,
total loss

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If machine is classified in category A, it can be certified.
If machine is classified in category B1, retesting of certain aspects is required1.
If machine is classified in category B2, the entire test process must be repeated.

Recommendations for improvement are not part of the mounting tests.

5. Mounting test of UHP/run-flat tyres - Data record and evaluation

During the mounting and demounting processes, the forces applied on the rim flange by
the tensile stress of the bead core will be recorded using a measuring rim.

This method should verify the subjective impressions regarding easy or difficult tyre
mounting operations by measuring force values.

The bead forces should not exceed the following values:

• for mounting: 1.0 kN

• for demounting: 1.5 kN

The measurement of the forces is an additional information for evaluation of the machine,
but those forces are not defined as limit values.

Measuring rim

1
The requirements for retesting will be defined by the wdk control board (consisting of representatives of
the tyre manufacturers, tyre trade, automotive industry and machine manufacturers).

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 2,5

Mounting by rotating Tyre slips at the point of

the rim traction over the rim
2
flange into the drop cen-
tre. End of mounting.

1,5
force in kN

0,5

0
0 2 4 6 8 10 12

-0,5
time in s

Forces during mounting process

Positioning of the Tyre slips at the

3,5 lever and lifting the point of traction
tyre out of the drop off the rim. End
centre. of demounting.
3

2,5

2
force in kN

1,5

0,5

0
0 5 10 15 20 25

-0,5
time in s

Forces during demounting process

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6. Rims

• 7.5x17 EH2 BMW light alloy

• 6.5x16 EH2 MEFRO steel rim

7. Tyres
The following tyre sizes and designs of the manufacturers, who are members of the wdk,
are used:

• 205/55 R 16
• 225/50 R 17

4 tyres 16" RFT

4 tyres 17" RFT
2 tyres 21" RFT (325/30 R 21) or 22" *

*The cross section ratio of special size tyres should not be more than 35%.

A separate agreement is required when testing the machine with rims larger than 22".

8. Documentation
The documentation must include:

• Name of the neutral testing agency

• Data record
• Test report

The data record must include:

• Tyre size and design

• Ambient conditions
• Wheel/rim data,
• Rim design / hump design
• Characteristics, categories of damage and failures classified according to the
specifications above - detected during the tests
• Mounting and demounting forces

The test report must include:

• A summary of the entire test cycle and annotations, statements, comments, if

any, regarding anomalies during the tests

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 Test result mounting - Handling
Date of test:

Inspector:

Tyre changers:
Manufacturer: Type:

Tyre:
Manufacturer: Size:
Temperature: No.:

Test wheel:
Size: Design:
Material:

Test for side 1

Use of standard accessories

All: Partly: None:
Flange protection: Yes: No:
Form of hold-down ( e.g. chain):

Test for side 2

Use of standard accessories

All: Partly: None:
Flange protection: Yes: No:
Form of hold-down ( e.g. chain):

Comments:
_______________________________________________________________________
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_______________________________________________________________________

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 Characteristics, errors and forces during mounting

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Characteristics, errors and forces during demounting

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 General instructions and recommendations

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Appendix
On following pages the general technical data and dimensions of passenger car tyres
and rims are shown and described. Source: Technischer Ratgeber PKW Continental

14
15
Run-flat tyres

The designations and abbreviations for run-flat tyres (RFT) and run-flat system compo-
nent (RSC) are both synonyms for the same technology: SST - a self-supporting tyre with
run-flat properties.

RSC stands for self-supporting tyre as part of the system of tyre, rim and early-warning
system. The label RSC was created by BMW Group together with the tyre industry as a
distinctive label for the BMW customer. Since October 2001 the letters RSC are visibly
imprinted on all BMW run-flat tyres (Source: BMW).

Due to stiffness of the tyre sidewalls, high forces occur during the mounting process.
These forces cannot be transferred completely and affect the bead area directly.

RSC, RPA and EH2

RSC achieves its effectiveness only in combination with another two components:

• Early warning system in form a flat tyre indicator (RPA or optionally a tyre
pressure control system (RDC)
• Special formed type of rim, the so-called extended-hump rim.

Only the combination of these three components makes the spare tyre superfluous. RSC
is therefore only used in the standardized package of tyre, rim and early-warning system
(Source: BMW).

The design of the EH2-rim improves the stability of the tyre rim system. The special fea-
tures which distinguish the EH2-rim from other rims are modified humps. They are extend
further inwards on both sides and are a little bit higher (Source: BMW).

The term UHP tyres is commonly used for a tyre with an aspect ratio of ≤ 45 %.

16
Tyre characteristics: e.g. 205/45R16 91 V

205 Nominal tyre width (mm)

45% Nominal cross-section ratio (tyre height is 45% of the nominal width)
R Symbol for radial ply tyre ** or RF for run-flat tyres
16 Rim diameter (inch code)
91 Load-carrying capacity index "91" means the tyre may be charged with a load
of 615 kg)
V Speed symbol for maximum admissible speed: V = 240 km/h

Meaning of the terms used above:

Tyre size See sidewall

Tyre type Radial - see sidewall
Tyre design RFT and UHP - see sidewall
Bead Part of the tyre that is connected with the rim
DOT Tyre code according to the Department of Transport (DOT) of the
USA; the identification with the date of manufacture is always des-
ignated as side 1 in the tests; date of production = 12 o'clock posi-
tion
Rim width Distance in inch, measured inside from rim flange to rim flange =
size A - see fig. on page 14
Hump Circumferential part on the rim shoulder, prevents the tyre bead
from slipping into the drop centre if tyre pressure is not sufficient
EH2 and EH2+ Different designs of rims for RF tyre; dimensions in the range of the
rim shoulder (EH2 = max. 55mm / EH2+ = max. 38 mm)

17