DVP Design ValidationTest for Brake System

Please read previous two blogs to know what is DVP, DVP Sequence, child part DVP, System DVP, Vehicle DVP, Different types of DVP Tests etc. 

Here only few design validation tests are proposed for Brake System : to know the specification and values of below table, please read previous blog of brake system design review, DFMEA and development. 

Child Part	Specification	Test Number **/ Duration Weeks	**Test Number : Part Level	Vehicle Level Test
Brake Pipe	Burst Pressure =2000Bar OD= 10mm Max ID=5mm Min Factor of Safety 10	1,2,3,4,5,6,7,8,10, 11,12,13,14, 15	1. Leak Test at 200Bar for 30 Second at -40 °C,140 °C 2. Burst Pressure Measurement 3. Joint Leakage Test 200 Bar for 30 Sec 4. Salt Spray (NaCl) 200 Hour No Red/White Rust 5. Material Test 6. Impact Test hit part by 10N Force / Drop Test: Drop part from 1m height: No mark or damage 7. Thermal Test: 2000 hour for 140 ° C 8. Heat Shock: 1 hour 0 °C to 1 hour 140 °C for 500 Cycle 9. Boiling Point Measurement from 1Bar to 200 Bar 10. Composite Durability: Pressure 0 to 200 Bar with Frequency 30 to 300 Htz at 20°C 11. 30g Vibration Test X, Y, Z Direction 100 Hours each at 300 Htz Frequency 12. Chemical Resistance: 100 Hour in Water, Oil 13. Dimension Test as per drawing 14. Tolerance, GDNT, Assembly Check 15. Hardness Test 16. Temperature Density Graph 17. Temperature Viscosity Graph 18. Fluid Compressibility 19. Water Content % Check 20. Voltage Graph 21. Current Graph 22. Resistance Graph 23. Pressure Graph 24. Pressure Sensitivity 25. Spring Constant 26. Grip, Sharp Edge, Ergonomics 27. Hand Brake Cable Braking Force Measurement 28. Cable Elongation	1. Vehicle will run 2000 Km on different type of road condition then all parts dimension will be checked. 2. Dynamic and Static Vehicle Test will be done when all parts are fitted on vehicle. Dynamic Test  1. Dry Brake Distance Test 2. Wet Brake Distance Test 3. Brake Pad Wear Test 4. Brake Pedal Force Test 5. Ramp Brake 6. Up/Down Hill Braking Test 7. Corner Braking 8. High Slip Braking 9. Flat/Wear Tyre Braking 10. Under Water Braking Test 11. Ice Braking Test 12. Brake Fail Test 13. Brake Sensor Test 14. Pedal Pressing Force 15. Pedal Displacement Fuel Cut Off Check   16. Brake and ECU Calibration 17. Pedal Displacement Speed Graph 18. Vehicle Deceleration  Static Test: 1. Leg Space Check 2. Ergonomics Check
		8
Brake Oil	No Compressibility, Anti Hygroscopic Nature, High Dry/Wet Boiling Point, Fix Viscosity and Density	9, 16,1718,19
		6
Disc	Mean Effective Radios = 250mm, Thickness = 20 mm Weight = 2 Kg Max	4, 5,6,7,8,10,11, 12,13,14,15,
		8
Piston	Dia =45mm, Burst Pressure = 250 Bar	1,2,3,4,5,6,7,8,10, 11,12,13,14, 15
		8
Master Cylinder	Bore =10mm, Capacity = 15cc Burst Pressure = 250 Bar	1,2,3,4,5,6,7,8,10, 11,12,13,14,15
		8
Brake Pad	Area =50Cm2 Depth =40mm Thickness =15mm	4, 5,6,7,8,10,11, 12,13,14,15,
		8
Brake Pedal	Level Length =300mm Pedal Area = 50X50mm2	4,5,6,78,10,11,12,13,14 15,23,24,25,26,27,28
		8
Brake Pressure Sensor	Pressure = 0 to 12 Bar Accuracy = 1% Voltage = 0 to 5Volt	20,21,22, 23,24,
		2
Hand Brake Lever	Length =300mm Handle Dia = 20mm Weight = 1Kg Max No Sharp Edge	4, 5,6,7,8,10,11,12,13 14,15,23,24,25,26
		8
Brake Cable Wire	Braiding, Ductility, Dia, Length	4, 5,6,7 8,10,11,12,13 14,15,23,24, 25,26,27,28

Next blog is Design Validation Plan for Steering System, Please read for more details. 

Previous blog was what, why, when, who, where and how about DVP. 5W1H of DVP. Read that too.