APRA European Symposium Krakow April 2012

Transcription

1 APRA European Symposium Krakow April 2012 Ian Buxcey European Remanufacturing Manager Didier Westphalen Site Manager Meritor Trucktechnic Belgium

2 The Company Profile Meritor is an automotive company, which engineers, manufactures and remanufactures totally integrated systems for the light and heavy commercial vehicle assemblers Sales: $4.6 billion

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

6 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 Million Joules - For a Porsche 911 to have the same kinetic energy it would need to be driving at 440 km/hr Million Joules is enough energy to light a 100W light bulb for 38 hours Million Joules is enough energy to do this to a disc brake Correctly performing brake Incorrectly performing brake

7 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

8 Stopping power Brake Performance Cold Performance T=100 C Best stopping distance correctly performing brake at working temperature 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

9 Brake Strength Truck OEM defines target Meritor calculates allowed loads Meritor test brakes 2 Stress locations (carrier alone method) 1 5 Meritor designs components 3 4 OEM test truck You drive truck

10 Output Load. kn Lever Travel. mm. (Hysyeresis %). But it is not that easy! Guide pin slide testing Adjustment function testing Rig/Vehicle: Environmental Cabinet GVW (kg): 0 Brake-F: ELSA225-5 for Irisbus Lining-F: Brake-R: N/A Lining-R: Schedule: Component amb Engineer: Pratt R. Hysteresis Output, Clamp Loads and Lever Travel File: Test 2 Amb P Test Date: Sliding Pressure for Caliper Components at Ambient (PG2) Lead Output kn 70 slide travel 1 mm (Max.= 5.86) (Mean = 5.66) pressure bar (Max.= 7.08) (Mean = 3.96) lead tappet 2 mm (Max.= 6.99) (Mean = 6.42) trail tappet 3 mm (Max.= 6.69) (Mean = 6.10) Temperature testing Trailing Force. kn 200 Total Output Force. kn 60 Lever Travel. mm Hysteresis % Time Secs Input Load. kn Adjustment life testing Fatigue testing Plus Water seal testing Slurry seal testing Vibration testing Salt Spray testing etc

11 Failure prevention looks at three factors Failure Prevention - 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

12 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

13 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

14 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

15 Core Recovery Center Basic Concept Material addition welding technologies High tolerance machining Plasma Transfer Wire Arc

16 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

17 Product Quality Validation

18 EU Reman Aftermarket Products Air Disc Brakes Differentials Compressors Air Dryers Valves Clutch Servos

19 Meritor Reman Caliper Process 1. Core Sorting Core Dismantling 2. QUALITY GATES QUALITY GATES 3. Pre-Assembly Assembly End of Line Test Packing & Labelling 6.

20 Meritor Reman Caliper Process -- You Profit -- Cost Saving, Product of high Quality and Same Warranty as New

21 CVA Europe Structure Head office Commercial desk Reman Facility Warehouse IAM Sales Managers OES Sales Managers

22 Thank you