APRA Krakow 2012

APRA European Symposium Krakow April 2012

Ian Buxcey European Remanufacturing Manager Didier Westphalen Site Manager Meritor – Trucktechnic Belgium

The Company Profile Meritor is an automotive company, which engineers, manufactures and remanufactures totally integrated systems for the light and heavy commercial vehicle assemblers.

2011 Sales: $4.6 billion

Technical Capabilities - Brakes European Brake Engineering Centre • Design and Development office - 2/ 3D design capability - Finite element analysis - Fatigue prediction - Noise and vibration analysis • 4.000 sqm Test Laboratory - Fully equiped brake test and develoment facility - Instrumentation department - Vehicle support garage • 55.000 sqm Brake Assembly Plant - High volume machining and assembly - Producing over 750k brakes pa - Additional pre- production machining and low call manufacturing facility

Mass • To stop a vehicle you need to convert all of the energy of motion to heat - A 44 Tonne truck driving at 90 km/hr has kinetic energy of 13.75 Million Joules - For a Porsche 911 to have the same kinetic energy it would need to be driving at 440 km/hr - 13.75 Million Joules is enough energy to light a 100W light bulb for 38 hours - 13.75 Million Joules is enough energy to do this to a disc brake

Correctly performing brake

Incorrectly performing brake

Torque • The Volvo D16G engine on the FH16 generates up to 3,550 Newton-meters of torque to get the vehicle moving • Each of the four Meritor air disc brakes on any Volvo tractor unit generates up to 30,000 Newton-meters of torque to stop the vehicle

3 Tonne

3 Tonne

Brake Performance Cold Performance T=100°C

Best stopping distance – correctly performing brake at working temperature

Stopping power

Real world brake performance is dependent on many factors

Stopping distance 2x best stopping distance – correctly performing brake cold

A poor performing brake will have even longer stopping distance

Pedal push strength

Brake Strength Meritor calculates allowed loads

Truck OEM defines target

Stress locations (carrier alone method)

Meritor test brakes

1 2

5

3

Meritor designs components

4

OEM test truck You drive truck

But it is not that easy! Adjustment function testing

Guide pin slide testing GVW (kg):

Brake-F: ELSA225-5 for Irisbus

Lining-F:

Brake-R: N/A

Lining-R:

Schedule: Component sliding @ amb

Engineer: R. Pratt

0

File: Test 2 Amb P

Test Date: 7-9-2005

Hysteresis Output, Clamp Loads and Lever Travel 250

Sliding Pressure for Caliper Components at Ambient (PG2) 8.00

12

8.00

80

8.00

Lead Output kN

70

Trailing Force. kN

5.33

4

5.33

4.67

2

4.67

6 .1 0 )

6 .4 2 )

Total Output Force. kN

6.00

5.33

60

Lever Travel. mm

Temperature testing

Output Load. kN

6.00

6 .6 9 ) (M e a n =

6

6.67

(M a x.=

6.67

6 .9 9 ) (M e a n =

3 .9 6 )

8

7.33

(M a x.=

6.00

7.33

7 .0 8 ) (M e a n =

6.67

10

(M a x.=

5 .8 6 ) (M e a n =

7.33

(M a x.=

5 .6 6 )

200

Hysteresis % 50

150

40 100

30

7.50

15.00

22.50

30.00

37.50

4.00 45.00

4.00

trail tappet 3 mm

0 0.00

lead tappet 2 mm

4.00

pressure bar

slide travel 1 mm

20 50 4.67

10

0

0 0

Time Secs

2

4

6

8

10

12

Input Load. kN

Fatigue testing

Adjustment life testing Plus Water seal testing Slurry seal testing Vibration testing Salt Spray testing etc

14

16

Lever Travel. mm. (Hysyeresis %) .

Rig/Vehicle: Environmental Cabinet

Failure Prevention Failure prevention looks at three factors - Failure Detection – can an imminent failure be found before it occurs » Difficult to identify structural cracks as brakes are in a dirty environment » Difficult to identify internal issues until the mechanism stops working as brakes are closed units - Severity – does the failure cause a risk to life » A brake failure on a truck can cause:  Significant increase in stopping distance  Jacknife due to braking imbalance  Vehicle roll away » All are a potential risk to life, so severity is always high

- Occurrence rate – is the product of sufficient quality to not have a failure » OEMs spend vast sums of time and money ensuring this

Remanufacturing Solutions • With our OE knowledge we are able to develop high level standards for remanufacturing

• Ensuring that our remanufactured products operate as efficiently as an original • Giving our customers the guarantee that a remanufactured product from Meritor will offer safe and reliable performance

Engineering Center Supports the World Wide Aftermarket

WW Technical Requests • DMO Redesign • Resourcing PPAP’s • All Makes Engineering • Reman Recovery Validation • Product Audit and Testing

Product Engineerin g Support

Engineering Center Output • Material Specifications • GD&T Specifications • Process Approvals • Test Reports

Aftermarket product engineering support gives the world wide business dedicated resources for quality assurance and faster growth

Product Engineering Support Bangalore Technical Centre Technical competence for distribution and remanufactured product Business Case • Gain Design Control of All Makes Product • Design price point product • Create resourcing opportunities • Improved Supplier Quality • Qualification of Reman Wear Criteria Acceptance • Qualification of Reman Core Recovery Techniques

Core Recovery Center Basic Concept • Material addition welding technologies • High tolerance machining

Plasma Transfer Wire Arc

Product Quality Validation • test and test again - Continuous Validation tests – Structural & Durability - Benchmark tests Versus the OE equivalent Caliper - Under the advise and expertise of Meritor OE engineers

Product Quality Validation

EU Reman Aftermarket Products

Air Disc Brakes

Compressors

Differentials

Air Dryers

Valves

Clutch Servos

Meritor Reman Caliper Process

5. End of Line Test 6.

QUALITY GATES

3. Pre-Assembly

Core Dismantling 2. QUALITY GATES

1. Core Sorting

Assembly 4.

Packing & Labelling

Meritor Reman Caliper Process

-- You Profit -Cost Saving, Product of high Quality and Same Warranty as New

CVA Europe Structure Head office

Commercial desk Reman Facility Warehouse IAM Sales Managers OES Sales Managers

Thank you