Creation of a test specification for electric earth-moving machines

Status:

completed 02/2025

Aims:

In recent months, the DGUV Test testing and certification body of the DGUV’s Expert committee Construction has received a growing number of requests for testing of electrically powered construction machinery. In other sectors too, machines employing internal combustion engines are increasingly being replaced by machines powered by electric motors. A number of electrical safety requirements must be met during operation of such machinery and, where applicable, charging of batteries. Since a test specification summarizing the requirements applicable to electrically powered construction machinery and describing harmonized test procedures is not currently available to the test centres of the German Social Accident Insurance Institutions, the purpose of this project was to draw up such a test specification.

Activities/Methods:

Creation of the test specification began with compilation of legal and normative requirements. In addition, existing test specifications and test methods from other industries were studied to determine whether certain aspects could be covered by the adoption of test methods described in the past. The outcomes were then compiled in a new test specification for the test and certification bodies in the Expert committee Construction. The requirements concerning electrical hazards on electric construction machinery are listed in the first part of the specification, which is accessible to the public. The second part of the test specification, which is not publicly accessible, describes the test methods that are necessary for verification of requirements. The second part also specifies the qualifications required of the person performing the test (skilled electrician, person who has received electrical instruction, etc.). The test specification was validated and adapted in a test prior to publication.

Results:

As the safety requirements for the machines under consideration are not clearly defined in standards for earth-moving machinery, a comprehensive survey of standards was conducted at the beginning of the project. This survey included existing check lists from the DGUV Test network, and discrete requirements set out in relevant standards. To enable the requirements to be formulated as precisely as possible, a range of electric earth-moving machines from a number of manufacturers were examined in conjunction with the BG BAU. To evaluate the test specification, a complete electrical safety test of a relevant machine was performed against the test specification at the manufacturers’ premises. The findings gained during practical application of the test specification enabled it to be revised in the interests of efficiency and ease of use.

As planned, the final version of the test specification is divided into two parts. The first part summarizes all requirements, broken down by subject. The second part contains a clear check list. The test specification will be published by the BG BAU and used in future during consulting with manufacturers of electric earth-moving machinery, and will also be applied by the test body during testing of such machines. Plans are for the IFA to provide support for future tests commissioned by the BG BAU.

Last Update: