Abstract
In this article, the strategy followed by an automobile company for detecting the root causes of groan complaints related to rear drum brakes in commercial vehicles is presented using data collected from the sold troubled vehicles and from new vehicles from the production line, as well as the drum-brake test rig at the laboratory. Drum brake groan is often very intense and can cause large numbers of customer complaints. During a groan noise event, vehicle structure and suspension components are excited by the brake system and result in a violent event that can be heard and felt during brake application. This paper condenses experimental studies on a low frequency drum brake groan problem that has caused high warranty costs. First, the environmental conditions causing the groan were identified and the groan was reproduced. Vehicle tests were performed both at the factory and in traffic. To conclude the planned study, TVA (Total Value Analysis) and FMEA (Failure Mode and Effects Analysis) methods were used effectively. A strategy to determine the root causes was planned and implemented systematically to eliminate the secondary and tertiary effects of brake groan problems. In order to ge to the root causes, vibration and groan measurements were executed and interpreted according to TVA and FMEA charts. The sensitivity of the lining material of the brake shoes to different environmental conditions was investigated. Finally, the groan mechanism of the drum brake system is discussed and the solution to the low frequency drum brake groan problem is evaluated in detail.
Highlights
In this article, the strategy followed by an automobile company for detecting the root causes of groan complaints related to rear drum brakes in commercial vehicles is presented using data collected from the sold troubled vehicles and from new vehicles from the production line, as well as the drum-brake test rig at the laboratory
We report on the following: 1. taking a vehicle from the production line with a troubled drum brake, 2. lifting the vehicle and disassembling the troubled drum brake, 3. using two pieces of cloth and hot water to moisten the lining material on the shoes, 4. wrapping the cloth around the shoes for 5 minutes, 5. observing the surfaces of the lining material to see whether there are any changes, 6. mounting the disassembled brake parts quickly to prevent drying of the brake lining, 7. driving the vehicle under maximum control to determine whether the troubled brake makes noise and creates vibrations
The detection and solution of the problem can be carried out using industrial engineering tools such as total value analysis (TVA) and FMEA methods
Summary
Value analysis (VA) or total value analysis (TVA) and value engineering can be defined as an organized and systematic approach to providing the required function at the lowest cost consistent with specific performance, quality, and reliability. Identify the control point and devise a plan for periodic measurement of the performance and correct the deviations if any
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