SBIR Phase I: Tools for Improved Friction Material Processing

SBIR 第一阶段：改进摩擦材料加工的工具

• 批准号: 0945455
• 负责人: Donald Yuhas
• 金额: $ 15万
• 依托单位: Industrial Measurement Systems Inc.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2010
• 资助国家: 美国
• 起止时间: 2010-01-01 至 2010-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0945455&HistoricalAwards=false
• 关键词: SBIR; Phase; Tools; Improved; Friction

This Small Business Innovation Research (SBIR) Phase I project aims to enhance the automotive friction material manufacturing industry's productivity and efficiency by providing a superior measurement method for quality, consistency and the quantification of noise influencing material properties. Friction material manufacturing is subject to inter-material as well as inter-batch inconsistency that is not adequately quantifiable by existing methods. These inconsistencies adversely affect customer satisfaction, contribute to lost business and consume engineering and testing resources. An ultrasonic-based measurement method capable of measuring material property and consistency data has been employed in destructive laboratory testing with success. Modification of this method for use with intact, as-manufactured friction materials can provide manufacturers with the quality and consistency analysis tools that are currently severely lacking. In this program studies will be conducted to relate ultrasonic data to friction material processing variables and to forge a relationship between ultrasonic test data and noise performance. Ultrasonic measurement can be implemented as both, part of a control scheme to improve the manufacture of friction materials and as a quality assurance method to ensure that noise-prone components do not enter the marketplace. Both lead to increased customer satisfaction and significant gains in manufacturing efficiency. The broader impact/commercial potential of this project is improved manufacturing processes for automotive friction materials. The entire automotive industry can attest that brake noise, vibration and harshness (NVH) repairs often dominate warranty claims. More than $100 million is spent annually on brake noise, vibration warranty work in North America alone. In order to reduce such warranty and brake repair costs, more attention is being placed on optimizing NVH performance to eliminate brake squeals, groans and other related issues at the original equipment level. This is especially true considering new vehicle quality perceptions are often driven in part by brake performance and warranty repairs. Although test methods suitable for measuring and controlling friction levels are available, methods to screen parts for the purpose of eliminating NVH problems are inadequate, lacking sufficient specificity to allow definitive screening for the elimination of defective components. These methods are expensive, slow and difficult to implement. Better quality assurance test methods are needed, which market ultrasonic measurement methods are fully capable of exploiting. Ultrasonic methods fit a need in the auto industry that has not been filled, despite much time and effort being devoted to NVH over the past few decades.

这项小型企业创新研究（SBIR）第一阶段项目旨在通过提供一种卓越的测量方法来测量影响材料性能的噪声的质量、一致性和量化，从而提高汽车摩擦材料制造业的生产率和效率。摩擦材料制造受到材料间和批次间不一致的影响，现有方法无法充分量化。这些不一致会对客户满意度产生不利影响，导致业务损失，并消耗工程和测试资源。一种能够测量材料性能和一致性数据的基于超声的测量方法已成功地用于破坏性实验室检测。对该方法进行修改，使其适用于完整的成品摩擦材料，可以为制造商提供目前严重缺乏的质量和一致性分析工具。本项目将研究将超声数据与摩擦材料加工变量联系起来，并建立超声测试数据与噪声性能之间的关系。超声波测量既可以作为控制方案的一部分来改进摩擦材料的制造，也可以作为质量保证方法来确保容易产生噪声的部件不会进入市场。两者都能提高客户满意度，并显著提高生产效率。该项目更广泛的影响/商业潜力是改进汽车摩擦材料的制造工艺。整个汽车行业都可以证明，刹车噪音、振动和粗糙度（NVH）维修往往是保修索赔的主要内容。仅在北美，每年就有超过1亿美元用于刹车噪音、振动保修工作。为了降低保修和制动维修成本，人们更加关注优化NVH性能，以消除原始设备层面的制动尖叫、呻吟和其他相关问题。考虑到新车质量观念往往部分由制动性能和保修维修驱动，这一点尤其正确。虽然有适合测量和控制摩擦水平的测试方法，但为了消除NVH问题而筛选部件的方法是不充分的，缺乏足够的特异性来确定筛选以消除有缺陷的部件。这些方法昂贵、缓慢且难以实现。需要更好的质量保证检测方法，而市场上的超声波检测方法完全有能力开发。尽管在过去的几十年里，人们在NVH方面投入了大量的时间和精力，但超声波方法适合汽车行业的需求，这一需求尚未得到满足。