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Complying with the laws on safety that cover both employees and consumer products can be an intricate business, but one which it pays to get right. Get it wrong and you not only risk seriously damaging your corporate reputation, losing a great deal of money and causing injury or death you could even find yourself serving a prison sentence. In this article Neil Roche, automotive approvals expert at TRaC-TRL, highlights what manufacturers need to know.

Safety is a big issue for vehicle manufacturers and, according to European Commission figures, in 2007 15% of the products notified under RAPEX1 were motor vehicles. This made them the second largest category after toys (at 31%). Most of the motor vehicle notifications were associated with 'risks of injury' often combined with the risk of 'fire '.

The most common measures requested as a result of a notification are a ban on sales, withdrawal of a product from the market, provision of information to consumers about the risk identified, or a full product recall. However, these measures are not 100% successful in eliminating risk. In the case of motor vehicles, product recalls seem to result in around an 80% return at best. So it is clearly in the interests of both manufacturers and consumers for vehicles to be tested appropriately before being released for sale.

Britain leads Europe as the most diverse and productive vehicle manufacturing country. There are more than 40 companies manufacturing vehicles here, ranging from global volume car makers, van, truck and bus builders, to specialist niche players. The industry is supported by a dynamic supply chain including many of the world's major component manufacturers, technology providers, design and engineering consultancies. The principal challenge for the industry is to align its technology, product and business performance to deliver customer value in a global industry subject to relentless cost-cutting pressures. Using a specialist test house to advise on the selection of appropriate approvals for international markets and design a programme of testing that is streamlined, fast and efficient for specific products will help to save valuable time and money in both the short and the long term.
use of electronic components means that the Automotive EMC Directive is the probably the single most
significant one.

The Automotive EMC Directive requires manufacturers to gain type approval for all vehicles and electronic sub assemblies, components and separate technical units to be used in vehicles. Certain types of equipment are exempt from particular tests. Equipment for caravans and motor homes, for example, that operate when the vehicle is in use are included in the Directive, but those that only operate when the vehicle is immobilised (parked) or are powered independently are excluded.

Safety and fitness for purpose in the context of the Automotive EMC Directive (2004/104/EC) mean that: a) the electrical noise from the product is kept within defined limits, that protects other electrical equipment and radio broadcast services and; b) is immune to the electrical noise produced by the vehicle and other electrical equipment used in close proximity to the product.

The introduction of the current Automotive EMC Directive (2004/104/EC) provides greater flexibility for the manufacturer where the product does not have an 'immunity related function'. It enables such equipment to not require 'type approval' but allows for the use of limited tests simply checking the radiated emissions it produces and immunity to conducted transients. Figure 1 (see next page) provides guidance on the applicability of the automotive directive and the overlap
 
 
 
 
 
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