DFMEA of Bicycle system

Systems and Subsystem

Frame
Sprocket-pedal
 Top tube
 Pedal/crank arm
 Down tube
 Seat tube/stay Chain-Derailleur
 Chain stay Seat
 Saddle
Front wheel
 Seat post
 Spokes
 Hub Handbrake
 Rim
 Brake lever
 Tire
 Brake cable
 Brake pads
Rear wheel
 Brake caliper
 Spokes
 Hub
Suspension
 Rim  Front Forks
 Tire
 Seat springs
System Bicycle DFMEA / NO
Subsystem Braking system PREPARED BY
Component Handbrake DATE
Model xxxx CUSTOMER PART
NO
Team DRG NO

DFMEA SEQUENCE
RESPON
ACTION RESULTS
SIBILITY
POTENTIAL CURRENT
POTTENTIAL &

OCCUR

DETEC
POTENTIAL CAUSES (S) DESIGN RECOMMENDE

RPN
SEV

ITEM/FUNCTION EFFECT (F) TARGET

FAILURE MODE /MECHANISM CONTROLS D ACTION ACTIONS

OCC

RPN
DET
SEV
OF FAILURE COMPL
(S) OF FAILURE PREVENTION TAKEN
ETION
DATE
There is no Brake lever Run durability
Brake
actuation of design cannot Design review test and re-
Brake lever cut 7 2 4 56 x lever re- 3 1 9 27
Brake lever - braking sustain enough of brake lever design lever
designed
mounted on the action force system
handlebars for the
Brake lever
rider to have Ergonomic
doesn’t Brake lever Re-design of
sufficient leverage Brake lever design for Brake
provide proper too tight or lever, pivot
and travel to 5 clutch 3 less effort 3 75 x lever re- 2 2 8 32
leverage or difficult to point and
actuate the brake. mechanism and easy designed
doesn't travel grip mounts
operation
all the way

Fatigue cracks Check for Diameter

Adequate
in cable due to cable thickness of
6 3 5 84 x cable 4 2 7 56
inadequate diameter the cable
thickness
Brake Cable - The thickness thickness increased
brake cable Failure of
provides adjustable cable pull Corrosion of
and calibrated brakes, cable/ cable Check cable Selection of
Cable
movement unable to material material and cable material
Cable breaks 7 2 4 56 x material 2 1 9 18
between the brake close brake cannot tensile stress and outer
changed
lever and brake calipers withstand strength covering
caliper tensile force
Cable too tight Brake
Check cable Increase cable
4 from lever to 5 2 40 x cable slack 2 1 8 16
length length
caliper given

Design-related
Review of
pressing Reduce
No proper overhang of
Brake pads overhang to overhang or no Reduced
braking 5 2 brake pads 5 50 x 3 1 6 18
edge wear out completely overhang of overhang
Brake Pads - Brake action with back
utilise the brake pads
pads apply friction plate
friction surface
against the wheel
rim and stop Doesn’t No contact
Re-design
provide between Insufficient Design review Re-check brake
of brake
enough friction brake pad 6 thickness of 3 of brake pads 6 108 pad thickness x 4 2 8 64
pad
to stop the and wheel brake pads thickness and tolerances
thickness
wheel rim
Brake caliper -
Brake caliper Design brake
Caliper arms Design review
houses the brake No clearance caliper arms
pressed against of brake Re-design
pads which pushes Brakes lock between the for more
the wheel rim 8 2 calipers and 6 96 x of caliper 3 2 8 48
and presses it up caliper and clearance
when not clearance of arms
against the wheel wheel allowing for
actuated assembly
rim when actuated travel
via cables

 Submitted by Harshan