Analyzing Motor Fan Failure in field vehicle by QC tools

PREEPARED BYADHIR BAL.B

Reg No:2013286001

ME in Quality Engineering & Management

AREA OF ANALYSIS:

BASICS ABOUT MOTOR FAN APPLICATION:

• Electrically operated DC motor fan helps to cool the heat exchangers.

• Heat exchangers supportive for AC Performance and Engine cooling

• Motor subjected to operation with input from ECU

• Motor fan operated is a suction type fan.

• Motor fan parts as explained in the fig.

CONDESER

AIR GUIDES

AIR GUIDES

BUMPER

FAN MOTOR

CONDNSER PERFOMANCE RELATED PARTS MOTOR FAN Parts

Radiator

FAN

MOTOR

SHROUD

MOTOR Parts

OBJECTIVE OF THE ACTIVITY :

To collect and prioritize the customer voice respect to failure.

Perform failure detection and to identify the failure mode.

Identify the Root cause of failure mode.

Engineer the counter measure and confirmation on countermeasure.

NEED FOR THE STUDY:

Customer satisfaction.

Important safety parameter.

Question on reliability of vehicle

Brand image will be affected.

LITERATURE REVIEW

Author Contribution

Marsot (2005) Showed how the ‘‘Quality Function Deployment’’ method has been geared to ergonomics consideration in product design.

Science direct S0307904X1300724

Integration of ECQFD, TRIZ, and AHP for innovativeand sustainable product development

METHODOLOGIES DEFINED:

QFD

Description:Quality function deployment (QFD) is a “method wily to transform qualitative user demands into quantitative parameters,

Where it is used here?Analyze the customer voice to rate accordingly.

Fault Tree

Analysis

Description:Fault tree analysis (FTA) is a top down, deductive failure analysis in which an undesired state of a system is analysed using Boolean logic to combine a series of lower-level events. Where it is used here?Used as a failure detection tool for Motor failure

WHY WHY

Analysis

Description:Used to explore cost and effect underlying a particular problem. Technique to identify the root cause or problem by repeating the question why.Where it is used here?Used to identify the root cause for the detected failure.

CUSTOMER VOICE [QFD]: Customer complaint against design points

MOTOR FAN FAILURE

VEHICLEVEHICLE

EXERNALEXERNAL

ELECTRIC CIRCUIT ISSUE

ELECTRIC CIRCUIT ISSUE

FUSE OPEN [40A]FUSE OPEN [40A]

ARMATURE WIRE SHORT CIRCUIT

ARMATURE WIRE SHORT CIRCUIT

Theme Check Item JudgmentSuspected Cause

CYCLE TESTCYCLE TEST

Parameters

MECHANICAL FAILURE [BEARING

LOCK]

MECHANICAL FAILURE [BEARING

LOCK]

MOTORMOTOR

Results

ISSUE

COMMUTATOR FILLING

COMMUTATOR FILLING

BRUSH WEARBRUSH WEAR

BRUSH TERMINAL SHORT CIRCUIT

BRUSH TERMINAL SHORT CIRCUIT

FOREGIN MATERIAL IN FAN

FOREGIN MATERIAL IN FAN

FLOOD WATERFLOOD WATER

CIRCUIT CHECK CIRCUIT CHECK

PHYSICAL CHECKPHYSICAL CHECK

MULTIMETER CHECKMULTIMETER CHECK

MULTIMETER CHECKMULTIMETER CHECK

PHYSICAL CHECKPHYSICAL CHECK

LOOP CHECKLOOP CHECK

ECU SIGNALECU SIGNAL TAB BOOK CHECKTAB BOOK CHECK

MARK IDENTIFICATION

MARK IDENTIFICATION

WATER MARK IDENTIFICAITONWATER MARK

IDENTIFICAITON

BURN INTITATED AREA

BURN INTITATED AREA

SIMULATION OF FAILURE

SIMULATION OF FAILURE

FTA FOR FAILURE MODE ANALYSIS