Case Study:
Introduction
This case study examines the failure of engine hanger bushes in scooters manufactured by a reputed two-wheeler manufacturer. The investigation involved several weeks of field observation and discussions with scooter owners, leading to the identification of the root cause of the issue.
Background
The two-wheeler manufacturer, known for its commitment to quality and innovation, had recently introduced a new model of scooters that featured modifications to the engine design. These modifications were aimed at improving performance and fuel efficiency. However, shortly after the launch, reports of engine hanger bush failures began to surface among users.
Problem Statement
Scooter owners reported excessive vibrations and noise from their vehicles, which led to premature wear and eventual failure of the engine hanger bushes. This issue not only affected the performance of the scooters but also raised concerns about safety and reliability among customers.
Methodology
The investigation into the engine hanger bush failures involved:
1. Field Observations: Engineers conducted site visits to gather data on affected scooters. They observed the vibration levels during operation and noted any visible signs of wear on the engine hanger bushes.
2. Interviews with Owners: A series of interviews were conducted with scooter owners who experienced issues. The aim was to understand their experiences, usage patterns, and any modifications they had made to their vehicles.
3. Technical Analysis: The engineering team performed a detailed analysis of the modified engine design, focusing on its natural frequency and how it interacted with the vehicle's chassis.
Findings
After weeks of thorough investigation, several key findings emerged:
1. Increased Vibrational Frequencies: The modifications made to the engine design altered its natural frequency. This change resulted in increased vibrational forces being transmitted to the engine hanger bushes during operation.
2. Material Fatigue: The original specifications for the engine hanger bushes were not designed to withstand the higher vibrational loads caused by the modified engine. This mismatch led to accelerated material fatigue and eventual failure.
3. User Modifications: Some scooter owners had made additional modifications (e.g., aftermarket exhaust systems) that further exacerbated the vibrational issues, leading to even faster wear of the bushes.
Root Cause Analysis
The root cause of the engine hanger bush failure was identified as follows:
- Modification Impact: The changes made to the engine's design inadvertently shifted its natural frequency outside of optimal operating conditions. This shift resulted in resonance phenomena that intensified vibrations transmitted through the frame.
- Design Oversight: There was a lack of comprehensive testing for vibrational impacts during the development phase, which should have included simulations and real-world testing under various conditions.
Recommendations
To address this issue and prevent future occurrences, several recommendations were proposed:
1. Redesign Engine Hanger Bushes: Develop new engine hanger bushes using materials that can better absorb increased vibrations or redesign them with enhanced structural integrity.
2. Conduct Comprehensive Testing: Implement rigorous testing protocols for all new engine designs, including vibrational analysis and real-world simulations before market release.
3. Customer Communication: Educate customers about potential impacts of aftermarket modifications on vehicle performance and safety, encouraging them to consult with authorized service centers for upgrades.
4. Feedback Loop: Establish a feedback mechanism for customers to report issues promptly, allowing for faster identification and resolution of potential problems.
Conclusion
The case study highlights how modifications intended to enhance performance can inadvertently lead to significant issues if not properly tested and evaluated. By addressing these challenges through redesigns and improved testing protocols, the two-wheeler manufacturer can restore customer confidence and maintain its reputation for quality in a competitive market.
Copyright © 2024 AutoRubberConsulting - All Rights Reserved.
Powered by GoDaddy
We use cookies to analyze website traffic and optimize your website experience. By accepting our use of cookies, your data will be aggregated with all other user data.