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Supplement I I Presentation of Dr. James T. Trainor J. T. Trainor Testing Co. LLC BMC/SAE J2430 Dynamometer Test Program (Standardized Effectiveness Test for Aftermarket Brake Friction Products) Presented June 4, 2000, at the FMSI Annual Meeting Key Largo, Florida
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I) WHY A STANDARDIZED EFFECTIVENESS TEST FOR AFTERMARKET BRAKE FRICTION PRODUCTS?
1. POTENTIAL FOR GOVERNMENT REGULATION * * 1992 NHTSA REPORT & LETTER. * * CURRENT EFFORTS BY EUROPEAN FRICTION PRODUCERS FOR U.S. ADOPTION OF REG. 90 AFTERMARKET STANDARD. **ACTIVITIES BY OTHER COUNTRIES.
2. STRINGENT NEW VEHICLE BRAKE REQUIREMENTS **MAJOR OE FRICTION MATERIAL COMPOSITION CHANGES FOR FMVSS 135 AND CUSTOMER COMFORT REQUIREMENTS. **REPLACEMENT FRICTION SHOULD BE SUITABLE FOR THESE VEHICLES. **INCREASED TESTING TO AVOID UNEXPECTED PERFORMANCE.
3. INCREASING CUSTOMER INTEREST IN A STANDARDIZED TEST PROCEDURE FOR RELIABLE & CONSISTENT MATERIAL COMPARISONS.
4. ITS THE RIGHT THING TO DO: **LARGE NUMBER OF FRICTION PRODUCERS ** J661 CHASE TEST IS NOT A RELIABLE BASIS FOR ASSESSING
, VEHICLE BRAKING PERFORMANCE.
s:(/) **PUBLIC ASSUMES THERE ARE STANDARDS TO COVER SAFETY
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BMC/SAE J2430 DYNAMOMETER TEST PROGRAM REVIEW & UPDATE FOR FMSI JUNE 4, 2000
OCEAN REEF CLUB--KEY LARGO, FL. OUTLINE OF TOPICS
I) WHY A STANDARDIZED EFFECTIVENESS TEST FOR AFTERMARKET BRAKE FRICTION PRODUCTS?
II) KEY PROJECT OBJECTIVES Ill) BACKGROUND-KEY EVENTS (1987-1999) IV) SAE J2430 RECOMMENDED PRACTICE V) J2430 VALIDATION TESTING VI) J2430 APPLICATION TO AFTERMARKET PRODUCTS VII) ACCEPTANCE CRITERIA MEANING?
WHAT THEY DO NOT MEAN? VIII) CURRENT ACTIVITIES AND DIRECTION
IX} SUMMARY
J.T.TRAJNOR TESTING CO. LLC 8 RIVENDELL DR.
SHELTON, CT. 06484
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IX) SUMMARY-- CONTINUED
4. J2430 APPLICATION TO AFTERMARKET PRODUCTS **FIXED TEST CONDITIONS-EACH APPLICATION **ACCEPTANCE CRITERIA & SUMMARY GRAPHS **EFFECTIVENESS & FADE TEST ONLY
5. WHAT DOES MEETING CRITERIA MEAN/NOT MEAN: **GUIDELINES FOR QUANTITATIVI! & CONSISTENT MATERIAL ASSESSMENT ** CAN'T MAKE CONCLUSION ON INDIVIDUAL VEHICLE MEETNG FMVSS. ** J2430 INTENDED TO BE PART OF TESTING PROTOCOL. ** BMC/FMC POSITION PAPER
6. CURRENT ACTIVITIES ~ ** EXPAND INDUSTRY UNDERSTANDING & USE. **MECHANISM TO MAINTAIN ENGINEERING INTEGRITY **ANALYTICAL APPROACHES TO GENERALIZE
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IX) SUMMARY
1. WHY AN AFTERMARKET EFFECTIVENESS STANDARD ** NO U.S. GOVERNMENT STANDARD FOR AFTERMARKET **GOVERNMENTS MOVING TOWARD REGULATION **FUNDAMENTAL CHANGES IN FRICTION COMPOSITIONS ** CUSTOMERS WANT COMPARABLE PERFORMANCE DATA. ** CONSUMERS ASSUME STANDARDS. ** PREFER VOLUNTARY STANDARD.
2. SAE .12430 RECOMMENDED PRACTICE **SEVERAL TYPES OF USE. **PARALLELS FMVSS 135 ** RANGE OF DISC & DRUM BRAKE APPLICATIONS ** DETAILED FOR REPRODUCIBILITY & VALIDATION. ** NO PASS/FAIL ACCEPTANCE CRITERIA
3. VALIDATION TESTING **MATERIAL DIFFERENTIATION
s"T:T **TEST/TEST & LAB/LAB
~ ** DYNO/VEHICLE CORRELATION
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VII) CURRENT STATUS & ACTIVITIES
1. COMPANIES RUNNING J2430 TESTS ON AFTERMARKET PRODUCTS. **ASSESS MATERIALS & CONFIRM LAB/LAB REPRODUCIBILITY
2. COMMUNICATIONS TO BROADEN INDUSTRY UNDERSTANDING & USE. 3. ESTABLISH A MECHANISM TO MAINTAIN ENGINEERING INTEGRITY.
** IMPROVE THE J2430 PROCEDURE & REPORTING FORMAT ** INTRODUCE ADDITIONAL VEHICLE APPLICATIONS
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BMC FRICTION MATERIAL COMMITTEE POSITION PAPER
THE BMC/FMC POSITION PAPER WILL BE FOUND ON THE BMC WEB SITE (www.brakecouncil.org). **ENDORSE J2430 **DESCRIBE ACCEPTANCE CRITERIA & INTERPRETATION
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WHAT DOES MEETING ACCEPTANCE CRITERIA NOT MEAN?
1. SINCE ACCEPTANCE CRITERIA ARE BASED ON FIXED VEHICLE BRAKE SYSTEM PARAMETERS, THAT MAY DIFFER FOR AN INDIVIDUAL VEHICLE, MEETING THESE CRITERIA IS NOT A RELIABLE BASIS FOR CONCLUDING THAT AN INDIVIDUAL VEHICLE WILL OR WILL NOT MEET THE APPLICABLE FMVSS.
2. ACCEPTANCE CRITERIA ARE MINIMUM VALUES & DO NOT DISTINGUISH AMONG MATERIALS THAT MEET THESE LEVELS:
** MEETING THE CRITERIA DOES NOT SPECIFY THE BEST EFFECTIVENESS
FOR A GIVEN BRAKE APPLICATION.
3. J2430 IS NOT DESIGNED TO ASSESS OTHER IMPORTANT ASPECTS OF MATERIAL PERFORMANCE SUCH AS, NOISE, DURABILITY, DRUM/ROTOR COMPATIBILITY OR EXTENDED LIGHT DUTY SERVICE.
DECISION TO COMMERCIALIZE A FRICTION PRODUCT "TI SHOULD BE BASED ON A PROTOCOL OF TEST METHODS.
ien: J2430 IS INTENDED TO BE PART OF THIS PROTOCOL.
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VII\ WHAT DOES MEETING ACCEPIANCE CRITERIA MEAN?
1. FMVSS"s ESTABLISH MINIMUM VEHICLE BRAKE PERFORMANCE: * * SEVERE DUTY CONDITIONS. **DO NOT ADDRESS DURABILITY, NOISE OR TYPICAL SERVICE BRAKING CONDITIONS.
2. MATERIAL EFFECTIVENESS IS A MAJOR, BUT NOT THE ONLY FACTOR DETERMINING VEHICLE BRAKE PERFORMANCE:
** FRICTION PRODUCER DOI!S NOT KNOW CONDITIONS OF INDIVIDUAL
VEHICLES USING A FRICTION MATERIAL * * CANT RELIABLY PREDICT VEHICLE BRAKING PERFORMANCE OF AN
INDIVIDUAL VEHICLE FROM MATERIAL EFFECTIVENESS ALONE.
3. ACCEPTANCE CRITERIA ARRIVED AT BY DEFINING CERTAIN VEHICLE BRAKE SYSTEM PARAMETERS. WITH THESE PARAMETERS FIXED, FMVSS STOPPING DISTANCE & BALANCE CAN BE EXPRESSED IN TERMS OF MATERIAL EFFECTIVENESS AND MEASURED FROM J2430 DATA.
5. ACCEPTANCE CRITERIA PROVIDE A QUANTITATIVE ASSESSMENT OF MATERIAL ., EFFECTIVENESS THAT IS TIED DIRECTLY TO FMVSS REQUIREMENTS.
~ **INTENT IS THAT ACCEPTANCE CRITERIA SERVE AS USEFUL & REALISTIC
~ GUIDELINES TO PROVIDE A CONSISTENT, QUANTITATIVE BASIS ~ FOR ASSESSING MATERIAL EFFECTIVENESS.
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BMC OBJECTIVE
THE BMC FRICTION MATERIAL COMMITTEE OB.JECTIVE STATES IN PART:
THE BMC FRICTION MATERIALS COMMITTEE RESOLVES THAT AFTERMARKET BRAKE FRICTION MATERIALS SHOULD NOT DETERIORATE VEHICLE BRAKE PERFORMANCE BELOW THE APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARD, AND RECOGNIZES THAT ONVEHICLE, DYNAMOMETER, OR OTHER EQUIVALENT TESTING OR ENGINEERING OR COMPUTER ANALYSES MAY BE EMPLOYED BY MANUFACTURERS OF REPLACEMENT FRICTION IN MAKING GOOD FAITH EFFORTS TO DETERMINE FMVSS PERFORMANCE.
THE BMC FRICTION MATERIALS COMMITTEE RECOMMENDS:
i) AFTERMARKET FRICTION PERFORMANCE SHOULD BE TIED TO THE APPLICABLE FMVSS.
ii) BRAKE PERFORMANCE OF AN INDIVIDUAL VEHICLE IS INFLUENCED BY FACTORS IN ADDITION TO THE FRICTION MATERIAL BEING TESTED. FOR THIS REASON, THE FRICTION PRODUCER ~AKES CERTAIN ASSUMPTIONS TO DI!FINE VEHICLE SPECIFIC BRAKE PARAMETERS. BASED ON THESE PARAMETERS, FMVSS STOPPING DISTANCE AND BALANCE REQUIREMENTS CAN Bl! EXPRESSED IN TERMS OF
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II) KEY PROJECT OBJECTIVES
1. SINGLE END DYNAMOMETER TEST
2. PARALLEL FMVSS 135 ** BECOMING U.S. GOVERNMENT BRAKE PERFORMANCE STANDARD FOR HYDRAULIC BRAKE VEHICLES.
3. REPRODUCIBILITY * * LAB/LAB, AS WELL AS TEST/TEST **FUNDAMENTAL CHANGE FROM AlBIC COMPARISON TESTS
4. CAPABILITY TO DIFFERENTIATE AMONG MATERIALS.
5. APPLICABLE TO A RANGE OF VEHICLE BRAKES. **INITIALLY, VEHICLE SPECIFIC APPLICATIONS **WANT AN ANALYTICAL BASIS FOR BROADER ASSESSMENT OF MATERIAL ACCEPTABILITY.
5. ACCEPTANCE CRITERIA **SEPARATE DOCUMENTS FOR SAE RECOMMENDED PRACTICE & FOR APPLICATION TO AFTERMARKET PRODUCTS
., &. PUBLISHED AS SAE RECOMMENDED PRACTICE
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Ill) KEY EVENTS 1987--1995
1987
** SAE FORMS PASSENGER CAR BRAKE EFFECTIVENESS TASK FORCE
1992
** NHTSA LETTER TO AFTERMARKET COMPANIES & REPORT ON AFTERMARKET DISC & DRUM LINING PERFORMANCE.
1993
** BMC FRICTION COMMITTEE INITIATES SUPPORT FOR SAl! TASK FORCE **THREE PHASE PROGRAM:
I) SINGLE APPLICATION DISC TEST ii) SINGLE APPLICATION DRUM LINING TEST iii) GENERALIZED PROCEDURE WITH ACCEPTANCE CRITERIA
1994 ** DYNO & VEHICLE TESTING FOR J1652
1995
., ** SAE PUBLISHES J1652--SINGLE APPLICATION DISC BRAKE TEST ** BMC/FMC FUNDING FOR REAR DRUM BRAKE PROCEDURE 3:
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Ill} KEY EVENTS 1996--1999
1996
** SAE TASK FORCE REJECTS CONCEPT TO EXTRAPOLATE LINING PERFORMANCE ACROSS PLATFORMS
** BMC/FMC PUBLISHES OBJECTIVE--RELATES FRICTION MATERIAL PERFORMANCE TO FMVSS, NOT TO OE MATERIAL
** COMPLETE PROCEDURE & TESTING OF DRUM LINING PROCEDURE. -DECISION NOT TO PURSUE SAE STANDARD
** BMC/FMC SUPPORT SAE TASK FORCE FOR GENERALIZED PROCEDURE
1997
** FMVSS/EFFECTIVENESS MODEL **DRAFT GENERALIZED DISC & DRUM LINING PROCEDURE-J2430 ** BMC/FMC FUNDING FOR J2430 VALIDATION TESTING
1998
** INSTRUMENTED VEHICLE TESTING-5 VEHICLES ** ESTIMATE BRAKE INERTIA FROM FRONT/REAR BRAKE TORQUE RATIO
1999
** SAE PUBLISHED J2430 RECOMMENDED PRACTICE ** COMPANIES RUNNING J2430 TESTS **PRELIMINARY WORK ON ANALYTICAL APPROACH TO APPLY J2430
TO A BROADER RANGE OF VEHICLE BRAKES.
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J2430 PROCEDURE SYNOPSIS
I. CHECK BURNISH
NUIIBEROF SPEED APPLICATIONS kmlh
SUSTAINED
DECEL
z
5
SD-3
3
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10D-3
3
3 50.3
5 50 RAIIP
5
100
RAil~~!
INSTRUMENT CHECK COOLING CURVE
zoo 80.3
3
SUSTAINED PRI!SSURE
kPa
.. .75N
.
EFFECTIVENESS FADE
5 50 RAIIP
100
RAIIP
100.3
8.4
15 1ZQ.58 3
.
HOT PERFORMANCE COOLING
2 4
10D-3 50.3
1)BEST COLD EFFECT. 2)0500N.
3
RECOVERY RAIIP
2
100
RAIIP
REBURNISH
35 BD-3 3
EFFECTIVENESS
5 50 RAIIP
5
100
RAIIP
5
160
RAIIP
POST TEST COOLING CURVES
.
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INITIAL TEIIP. DRUIIIROTOR
DEG.C <100 100 100 100 100
100 100 100 55 FIRST SNUB
100 FIRST STOP 100 100 100
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IV) SAE J2430 RECOMMENDED PRACTICE
1. J2430 USEFUL FOR: * * QA TESTING ** FORMULATION DEVELOPMENT **BRAKE HARDWARE DESIGN/EVALUATION **AFTERMARKET MATERIAL CHARACTERIZATION
2. APPROVED & PUBLISHED BY SAI!-AUGUST 1999
3. PARALLELS FMVSS 135, NOT FMVSS 105 ** FMVSS 135 DYNAMOMETER SIMULATION TEST.
4. SUITABLE FOR A RANGE OF DISC & DRUM BRAKE APPLICATIONS **OUTLINES DATA REQUIRED TO RUN A SPECIFIC APPLICATION.
5. DETAILED SPECIFICATION-REQUIRED FOR REPRODUCIBILITY **ONLY ONI! WAY TO RUN EACH APPLICATION, NO OPTIONS.
7. NO PASS/FAIL ACCEPTANCE CRITERIA ** NO MEANING TO SAY A MATERIAL PASSES J2430
., 8. DESIGNED FOR EFFECTIVENESS & FADE EVALUATION
3: **NOT INTENDED TO ASS.ESS WEAR, NOISE, ROTOR WEAR ~ OR EXTENDED LIGHT DUTY VEHICLE SERVICE.
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IIFIGURE4
CARAVAN REAR DRUM LINING
.12430 AVERAGE SPECIFIC TORQUE
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FORD EXPLORER FRONT BRAKE
..12430 AVERAGE SPECIFIC TORQUE
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-12430 DYNOIVEHICLE CORRELATION
REGRESSED SPECIFIC TORQUE-RAMP APPLICATIONS
0.5
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VI) J2430 APPLICATION TO AFTERMARKET FRICTION PRODUCTS
1. SPECIAL CONSIDERATIONS I) EXACTLY SAME TEST CONDITIONS AT ALL LABS FOR A GIVEN BRAKE. **BRAKE HARDWARE SPECIFICATIONS **NEW OE ROTOR/DRUM EACH TEST **WHEEL LOAD **BRAKE COOLING CURVES **DYNAMOMETER SETUP CONTROL SHEET-EACH APPLICATION ** EXCEL PROGRAM TO VALIDATE EACH TEST PROCEDURE ** TEST LABS. HAVE HARDWARE & TEST CONDITIONS FOR THE 9 APPLICATIONS RELEASED TO DATE
2. SPECIFIC ACCEPTANCE CRITERIA-BASED ON FMVSS 135
** BCM/FMC RECOMMENDS MEET ALL CRITERIA
** SUMMARY GRAPHS
i) RAMP APPLICATIONS MEET FMVSS/EFFECTIVENESS SPACE
ii) COLD EFFECTIVENESS STOPS
., iii) HOT EFFECTIVENESS STOPS
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iv) FADE SNUBS v) POST TEST STRUCTURAL INTEGRITY
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1998 FORD EXPLORER 4 DOOR
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REQUIRED TEST PARAMETER
1. OE BRAKE PART NUMBERS: 1.1 FRONT BRAKE ROTOR 1.2 REAR DISC ROTOR 1.3 REAR DRUM U OE FRICTION
2. ROLLING RADIUS 3. WHEEL LOAD (CALCULATED FROM SPECIFIED INERTIA) 4. EFFECTIVE BRAKE INERTIA (FROM INERTIA ADJUSTMENT) S. PRESSURE APLY RATE BEFORE KNEE 8. PROP VALVE ACTIVATION PRESSURE 7. POST KNEE PRESSURE APPLY RATE 8. SUSTAINED TORQUE CORRESPONDING TO:
8.1 0.1Sg 8.2 0.31g . 8.3 0.85g 8.4 0.76g
u 0.80g
8.6 1.00g 9. SUSTMfED PRESSURE CORRESPONDING TO:
9.1 75 N PEDAL FORCE 9.2 500 N WITH POWER 9.3 500 N NO POWER 9.4 667 N WITH POWER 9.6 667N NO POWER 9.6118.5 N POWER
OTHER DATA FOR EFFECTIVENESS CALCULATIONS: 10. CENTER OF GRAVITY
10.1 GLLW
10.2 GGVW
11. WHEEL BASE 12. FULLY LOADED STATIC WEIGHTS
12.1 TOTAL VEHICLE 12.2 FRONT AXLE 13. LIGHTLY LOADED STATIC WEIGHTS 13.1 TOTAL VEHICLE 13.2 FRONT AXLE
UNITS
VEHICLE
m Kg KgmA2 kPals kPa kPa/s
N.m N.m N.m N.m N.m N.m
kPa kPa kPa kPa kPa kPa
mm mm mm
Kg Kg
Kg Kg
0.367 308
714 701 2832 2426 1160 2130 1144
FRONT BRAKE
REAR BRAKE
F67Z1125BA
F57A-20026-A
ABEX8083EE
ABEX6083EE
855 109 6290
363 46 8290 NO PROP. VALVE
449 928 1946 2276 2394 2992
3360 9214 2578 10231 3687 5432
185 383 803 939 988 1236
3295 9387 2605 10399 3738 5464
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SUMMARY ANALYSIS-AFTERMARKET FRICTION MATERIAL CHARACTERIZATION
I ISAMPLE BASED ON SAE J2430
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TOP#2 USTAINED PRESSURE (kPa) 1 - - - - - + - - - - - - j
IUSTAINED TORQUE (N.m) POST TEST STRUCTURAL INTEGRITY
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FRICTION FRICTION
MMAATNEURFIAALC:T~U~R-=E~R:-------
BRAKE APPLICATION:_ _ _ _ _ _ _ __ TEST LABORATORY_ _ _ _ _ _ _ ___
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..12430 AVERAGE SPECIFIC TORQUE
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J1653 COMPARISON OF COMMERCIAL DRUM LININGS
FMSI-242 CHEVY CAPRICE
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SAE J1652 COMPARISON OF COMMERCIAL DISC PRODUCTS
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V) J2430 VALIDATION TESTING
1. TOTAL PROGRAM ** OE & AFTERMARKET DISC & DRUM LININGS ** 250+ DYNAMOMETER TESTS--GREENING & LINK TESTING ** 12 INSTRUMENTED VEHICLE TEST&-GM & LINK WEST
2. DIFFERENTIATE AMONG MATERIALS **FIGURES 1 & 2 SUMMARIZE RESULTS FOR SEVERAL COMMERCIAL AFTERMARKET DISC & DRU,_, LININGS
3. TEST/TEST **FIGURES 3 & 4 SHOW DETAILS OF DUPLICATE .12430 TESTS ON DISC AND DRUM LININGS.
3. LAB/LAB
.
**FIGURE 5 SHOWS A COMPARISON OF LINK & GREENING RESULTS
FOR THE FORD EXPLORER FRONT DISC BRAKE
4. DYNAMOMETER/VEHICLE **FIGURE 6 SUMMARIZES DYNAMOMETER/VEHICLE CORRELATION FOR THE BRAKES TESTED. ** 1997 HONDA CIVIC; 1997 CARAVAN; 1997 GRAND PRIX; 1998 EXPLORER; 1998 F250.
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