Detecting Groan Sources in Drum Brakes of Commercial Vehicles by TVA-FMEA: A Case Study


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KARABAY S. , BAYNAL K. , Igdeli C.

STROJNISKI VESTNIK-JOURNAL OF MECHANICAL ENGINEERING, vol.59, no.6, pp.375-386, 2013 (Journal Indexed in SCI) identifier identifier

  • Publication Type: Article / Article
  • Volume: 59 Issue: 6
  • Publication Date: 2013
  • Doi Number: 10.5545/sv-jme.2012.809
  • Title of Journal : STROJNISKI VESTNIK-JOURNAL OF MECHANICAL ENGINEERING
  • Page Numbers: pp.375-386

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.