Didier Westphalen. Site Manager Meritor – Trucktechnic Belgium ... Schedule:
Component sliding @ amb. Engineer: R. Pratt. File: Test 2 Amb P. Test Date: 7-9-
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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
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