ilide.info-dfmea-of-bicycle-system-pr 2b35c143491cebb5a3dc3222d2410fd9

DFMEA of Bicycle system
Systems and Subsystem
Frame
 Top tube
 Down tube
 Seat tube/stay
 Chain stay
Front wheel
 Spokes
 Hub
 Rim
 Tire
Rear wheel
 Spokes
 Hub
 Rim
 Tire
Sprocket-pedal
 Pedal/crank arm
Chain-Derailleur
Seat
 Saddle
 Seat post
Handbrake
 Brake lever
 Brake cable
 Brake pads
 Brake caliper
Suspension
 Front Forks
 Seat springs

System
Bicycle
DFMEA / NO
Subsystem
Braking system
PREPARED BY
Component
Handbrake
DATE
Model
xxxx
CUSTOMER PART
NO
Team
DRG NO
DFMEA SEQUENCE
ITEM/FUNCTION
POTENTIAL
FAILURE MODE
POTTENTIAL
EFFECT (F)
OF FAILURE
SEV
POTENTIAL
CAUSES (S)
/MECHANISM
(S) OF FAILURE
OCCUR
CURRENT
DESIGN
CONTROLS
PREVENTION
DETEC
RPN
RECOMMENDE
D ACTION
RESPON
SIBILITY
&
TARGET
COMPL
ETION
DATE
ACTION RESULTS
ACTIONS
TAKEN
SEV
OCC
DET
RPN
Brake lever -
mounted on the
handlebars for the
rider to have
sufficient leverage
and travel to
actuate the brake.
Brake lever cut
There is no
actuation of
braking
action
7
Brake lever
design cannot
sustain enough
force
2
Design review
of brake lever
4
56
Run durability
test and re-
design lever
system
x
Brake
lever re-
designed
3
1
9
27
Brake lever
doesn’t
provide proper
leverage or
doesn't travel
all the way
Brake lever
too tight or
difficult to
grip
5
Brake lever
clutch
mechanism
3
Ergonomic
design for
less effort
and easy
operation
3
75
Re-design of
lever, pivot
point and
mounts
x
Brake
lever re-
designed
2
2
8
32
Brake Cable - The
brake cable
provides adjustable
and calibrated
movement
between the brake
lever and brake
caliper
Cable breaks
Failure of
cable pull
brakes,
unable to
close brake
calipers
6
Fatigue cracks
in cable due to
inadequate
thickness
3
Check for
cable
diameter
thickness
5
84
Diameter
thickness of
the cable
increased
x
Adequate
cable
thickness
4
2
7
56
7
Corrosion of
cable/ cable
material
cannot
withstand
tensile force
2
Check cable
material and
tensile stress
strength
4
56
Selection of
cable material
and outer
covering
x
Cable
material
changed
2
1
9
18
4
Cable too tight
from lever to
caliper
5
Check cable
length
2
40
Increase cable
length
x
Brake
cable slack
given
2
1
8
16
Brake Pads - Brake
pads apply friction
against the wheel
rim and stop
Brake pads
edge wear out
No proper
braking
action
5
Design-related
pressing
overhang to
completely
utilise the
friction surface
2
Review of
overhang of
brake pads
with back
plate
5
50
Reduce
overhang or no
overhang of
brake pads
x
Reduced
overhang
3
1
6
18
Doesn’t
provide
enough friction
to stop the
wheel
No contact
between
brake pad
and wheel
rim
6
Insufficient
thickness of
brake pads
3
Design review
of brake pads
thickness
6
108
Re-check brake
pad thickness
and tolerances
x
Re-design
of brake
pad
thickness
4
2
8
64
Brake caliper -
Brake caliper
houses the brake
pads which pushes
and presses it
against the wheel
rim when actuated
via cables
Caliper arms
pressed against
the wheel rim
when not
actuated
Brakes lock
up
8
No clearance
between the
caliper and
wheel
2
Design review
of brake
calipers and
clearance of
assembly
6
96
Design brake
caliper arms
for more
clearance
allowing for
travel
x
Re-design
of caliper
arms
3
2
8
48
 Submitted by Harshan