Quy trình thiết kế & chế tạo ô tô 12/2013

Quy trình thiết kế & chế tạo ô tô 12 2013 Một tạp chí rất hay về quy trình sản xuất và thiết kế từng chi các linh kiện, thiết bị trong ô tô.......

Trang 1

December 2013 BrakeandFrontEnd.com

Trang 2

Reader Service: Go to www.bfeRAPIDRESPONSE.com

Trang 3

Trang 4

BRAKE & FRONT END (ISSN 0193-726X)

(December 2013, Volume 85, Number

12): Published monthly by Babcox Media,

3550 Embassy Parkway, Akron, OH 44333 U.S.A Phone

(330) 670-1234, FAX (330) 670-0874 Periodical postage paid

at Akron, OH 44333 and additional mailing offices

POST-MASTER: Send address changes to BRAKE & FRONT END,

P.O Box 13260, Akron, OH 44334-3913 BRAKE & FRONT

END is a trademark of Babcox Publications, Inc registered

A limited number of complimentary subscriptions are available

to individuals who meet the qualification requirements Call

(330) 670-1234, Ext 288, to speak to a subscription services

representative or FAX us at (330) 670-5335 Paid

Subscriptions are available for non-qualified subscribers at the

following rates: U.S.: $69 for one year Canada: $89 for one

year Canadian rates include GST Ohio residents add current

county sales tax Other foreign rates/via air mail: $129 for

one year Payable in advance in U.S funds Mail payment to

BRAKE & FRONT END, P.O Box 75692, Cleveland, OH

44101-4755 VISA, MasterCard or American Express accepted.

CONTENTS

Volume 85, No 12

16

16 Alignment Spec

2004-2013 Mazda3

22 Brake Job

Stopping Brake Noise

24 Universal Joints

Inspection and Replacement

VICE PRESIDENT

Jeff Stankard jstankard@babcox.com 330-670-1234, ext 282

Sales Representatives:

Bobbie Adams badams@babcox.com 330-670-1234, ext 238 Doug Basford dbasford@babcox.com 330-670-1234, ext 255 Sean Donohue sdonohue@babcox.com 330-670-1234, ext 206

Jamie Lewis jlewis@babcox.com 330-670-1234, ext 266 Dean Martin dmartin@babcox.com 330-670-1234, ext 225 Glenn Warner gwarner@babcox.com 330-670-1234, ext 212 John Zick

jzick@babcox.com 949-756-8835

List Sales Manager

Don Hemming dhemming@babcox.co m

330-670-1234, ext 286

Classified Sales

Tom Staab tstaab@babcox.com 330-670-1234, ext 224

24 22

Trang 5

Trang 6

4December 2013 | BrakeandFrontEnd.com

Viewpoint By Andrew Markel | Editor

Telematics: Tomorrow’s

Diagnostic Nightmare

Every day you are exposed

to and benefit from

auto-motive standards Since

1916, the Society of Automotive

Engineers (SAE) has been

work-ing with OEMs and suppliers to

develop industry standards like

the shape of the OBD II

connec-tor (SAE J1930) to the

communi-cation protocols for the

serial data bus

and has enabled

for some diagnostic

procedures and

knowl-edge to work for multiple

vehicle manufacturers

Since the introduction of

OBD II in 1994, these

stan-dards have helped shops and

the aftermarket create a level

playing field while pushing

innovation forward at a lower

cost It is a great example of

how an industry can organize

for the good of everyone

It has also given consumers

better vehicles and more

serv-ice options It has been a real

“win-win.”

But, one of the biggest

trends in vehicles appears tohave no standards; I am talk-ing about telematics or the

“connected car.”

The best example of theramifications of the completelack of standards are

Mercedes-Benz’s Tele Aid and

early sion of GM’s OnStar Thesesystems were “bricked” due

ver-to the elimination of analogcell phone service Some ofthese cars were only threeyears old when the phoneand emergency assistance fea-ture stopped working in 2008

I am not scared that it will

be used to direct consumersback to the dealer or spy on

drivers, I am worried thattoday’s telematics systemcould be tomorrow’s diagnos-tic nightmare

This lack of standards willmake it more difficult to diag-nosis, repair or disable thesystem Newer systems aregoing further and are becom-ing nodes on the CAN bus.They can do more than just

observe data,they can bi-directional-

ly controlthe vehicle.This iswhy stan-dardsshould bedevelopedbefore atelematics mod-ule tries to dialMom with a transmis-sion control module

At the heart of the debate isthe clash of cultures Theautomotive industry takes atleast two years to develop aproduct that will last morethan 11 years The telematicsand cell phone industry willdevelop a product in sixmonths and it will need tolast only two years or untilthe next upgrade Cars have

to move slower because acrash is literally a crash ■

Trang 7

Trang 8

6 December 2013 | BrakeandFrontEnd.com

Have you noticed how

many automotive

reali-ty programs there are

on TV these days?

I take the time to sit downand take in a few of them hereand there But, from my side

of the wrench, I have a pletely different perspectivewhen watching them

com-In my opinion, some ofthese reality shows are farfrom reality

They’ll start off with one flashing a wad of cash ormeeting a deserving owner

some-Before the first commercialbreak, they tow the vehicle totheir garage and present it tothe crew The crew will lookshocked at what was justdropped off That’s about thetime the host gives them thelowdown in the next 40 min-utes on what’s going to take

place This usually consists of

a full restoration job, and only

a few weeks to get it

complet-ed By the end of the show,there’s a gleaming, fullyrestored work of art on thescreen

But the shows that reallydisturb me are those that usethe “all-nighter” approach tocar repair because they aredone “Hollywood-style.” Ateam will completely disman-tle a car to the shell and do all

Our Profession Is Greatly Underestimated By The ‘Big Screen’

Real or Reality TV

By Scott “Gonzo” Weaver Gonzosae@aol.com

Trang 10

8 December 2013 | BrakeandFrontEnd.com

the mechanical work, electrical,

interi-or, dash and instrument panels,

brakes, transmission, rear-end,

engine, cooling and heating systems,

replace the glass, and do a full paint

and body mod in less than a week

And, the best part (or biggest guffaw

on these shows) is the final reveal of

the newly restored gem to the

owner/buyer

On the sidelines, just out of the primary camera

view, is the entire crew that has spent the last three

days bringing this ride back to life I’m in awe of

the crew, to say the least Not one of them is

cov-ered in grease, or has half of their shirt untucked,

they have no fresh cuts or scraps, and not one of

them shows any signs of sleep deprivation

I’ve done my share of all-night, marathon repairs

before, and by the time the sun comes up, I’m not

the most coherent guy with a wrench They might

call it “reality TV,” but it doesn’t seem all that

real-istic to me I’m sure the entire staff involved are

some of the finest technicians, body-repair

special-ists and electrical gurus of the automotive world,

but I highly doubt you can turn out a truly

profes-sionally restored vehicle in that short amount of

time There has to be a huge number of shortcuts or

outsourced labor used to meet the deadlines

I do restorations all the time and the biggest

has-sle with any of them is parts availability The job

comes in the shop, you put it up on the lift and you

spin the driveshaft, only to find out the differential

or bearings are shot You can’t just run down to the

local parts store and expect to pick up a set of

bear-ings for a 30-year-old, low production car But,

somehow, some of these shows pull it off

On the other hand, there are a lot of great

auto-motive reality programs on the television that go to

great lengths to show how a modification is

accom-plished, with details that explain the process to the

“nth” degree Any show that portrays the reality of

doing the job I do every day in a professional

man-ner will get my attention I’ll sit down and watch it

from beginning to end You want to show me how

you install some super-cool, new rear taillight

lens-es or wild-looking front grille awlens-esome! Or,

pulling an engine out of a classic and doing the

necessary rebuild on it super! I love that stuff

But, when you try to convince me that you’re going

to take some car that’s been totally neglected andsitting for 10 years in the back of some familygarage, and you’re going to bring it back to lifeovernight then you’ve lost me

I think it gives the novice car enthusiast thewrong impression of what it takes to restore a car,and, for the typical customer, it greatly underesti-mates all that’s involved to fix his/her daily driver.Lately, I’ve been doing a lot more restoration proj-ects than I’ve done in the past, and I do believe it’s aresult of all of these reality shows So, for that, I’mthankful At the same time, shame on you! I can’tlive up to the overnight results that seem so possible

on the big screen Even though the customer doesn’tmention they’ve been watching a reality show, youknow what they’re thinking: “This shouldn’t takeany longer than it does on TV.” ■

Gonzo’s Tool Box

Trang 12

NUCAPIndustries, manufacturer

of the innovative NRS cal attachment system for brakepad backing plates, has partneredwith industry blog SAFEBRAK- ING.COMto offer an onlinebrake pad promotion TheSAFEBRAKING photo contest,launched on December 5th, askstechnicians to submit photos oftheir customer’s bad brake pads,and earn valuable Snap-on giftcards, plus a chance to win a tripfor two to the 2014 SEMA show

consciousness of aftermarkettechnicians and their suppliersabout a major problem facingthe replacement market

Adhesive bonded brake padbacking plates are a leadingcause of brake system noise,vibration and wear out issues.Not to mention that in the event

of a friction brake away, brakefailure could lead to a seriousaccident The best thing to do toavoid those issues is to use theNRS-equipped backing plates.SAFEBRAKING.COM isaddressing this head-on.”Learn more about NUCAP’sNRS technology and other prod-ucts at www.nucap.com

Go to www.bfeRAPIDRESPONSE.com

SAFEBRAKING.COM and NUCAP

Industries Partner in an Online Brake Pad Promotion for Technicians

Federated Auto Parts is now cepting nominations for the 2014Federated Shop of the Year

ac-Nominated shops will be ated on a set of criteria estab-lished by Federated and found onthe Shop of the Year nominationform Shops may be self-nominat-

evalu-ed or nominatevalu-ed by others Thewinning shop owner and guestwill be awarded a three-night,four-day all-expenses-paid trip toPhoenix as Federated’s guest atthe 2014 Federated NationalMeeting, receiving special recog-nition during the Federatedawards banquet

“The response to the FederatedShop of the Year program hasbeen terrific from the start and we

are looking forward to selectingour next winner,” said PhilMoore, senior vice president forFederated “Choosing only oneshop is a real challenge since thereare so many highly qualifiedshops around the country If youknow of a shop with knowledge-able, professional service techni-cians, superior service and repairsthat result in very satisfied cus-tomers, and active communityinvolvement, that shop could be

Federated Now Accepting Nominations For Shop Of The Year

Trang 14

the next Federated Shop of the Year.”

Last year’s winner, Weathers Motors, Inc

of Media-Lima, PA, was nominated by

Federated member Berrodin Auto Supply As

the winning shop owner, Larry Weathers III

accepted the award on behalf of Weathers

Motors

“There are worthy shops nationwide and

the Federated Shop of the Year program is a

wonderful opportunity to recognize the best

of the best, like Weathers Motors,” said John

Berrodin, president of Berrodin Auto Supply

“I encourage anyone who has experience with

a shop that meets the Shop of the Year

pro-gram criteria to nominate that shop for this

prestigious honor.”

For more information or to nominate a

shop, visit the Federated Auto Parts website at

rep-“To say I’m excited would be an understatement,” saidCramer “I must have entered 10,000 contests in my lifetime, andthis is the first time I won anything.” Cramer said he’s a bit of acar fanatic “I’m single, but I own five cars!” The RaybestosRattlesnake ups that to six Cramer’s son Eric, a deputy sheriffand retired Army Ranger, joined him at the presentation

The signature-edition truck was the grand prize in the brands’

Summer 2013 North American salespromotion The winning entry waspulled from more than 170,000 entries.Thanks to Toyota Racing

Development, a Toyota 5.7L minum i-FORCE DOHC 32-valve V8with a tuned TRD Supercharger helpsthe Raybestos Rattlesnake reach 600+

alu-hp It also includes a high-lift, off-roadsuspension and off-road shocks.Its stopping power comes from thesame Raybestos short track racingbrake package used by the Joe GibbsRacing team and the RaybestosRattlesnake stretches its off-road mus-cle with Raybestos Professional Gradechassis parts

Visit www.RaybestosGarage.com

for more information on the 2014Raybestos Rattlesnake Toyota Tundra

or to view video of the build

For questions regarding Raybestosbrand brake products, visit

RaybestosBrakes.comor call

800-323-0354 For more information onRaybestos chassis parts, visit

www.RaybestosChassis.comor call800-323-3022

Raybestos Rattlesnake Sweepstakes Winner Hits Jackpot In Vegas

Trang 15

Trang 16

v Industry Review

The “Best Tech of the Year”

award celebrates what

makes our industry great

— the technician WIX

Filters, a member of the

Affinia Group family of

brands, in conjunction with

Brake & Front End

maga-zine, named Bogi Lateiner

of 180 Degrees Automotive

in Phoenix as the 2013 Best

Tech of the Year

Bogi’s path to becoming

an automotive technician

was not a traditional one

After graduating Phi Beta

Kappa from Ohio’s Oberlin

College in just three years,

she did a “180.” Instead of

attending law school as

planned, she enrolled in an

automotive trade school and immersed herself in the

training necessary to become a technician

“After seven years of working as a master

techni-cian for BMW, I missed having a connection with

my customers,” Lateiner said “I

started a repair shop in my

driveway with little more than a

strong passion for educating my

customers and a commitment to

the highest quality of service

and repair I wanted to create a

shop where everyone could feel

comfortable and where I could

be a part of elevating the

reputa-tion of the automotive industry.”

Bogi opened the doors of 180

Degrees Automotive in early

2007, just months before the

onset of The Great Recession; a time when most

oth-ers were closing theirs Without any previous

busi-ness experience or an automotive upbringing (her

parents both worked for non-profits), Bogi lead 180’s

carport garage and single employee (herself)

through five years ofincreased sales, clocking inwith 2012 sales at $1-mil-lion-plus/year, six full-timeemployees, and the pur-chase and renovation of a $1million state-of-the-art,green-optimized servicefacility

One of the keys to Bogi’ssuccess has been customereducation Beyond teachingcar-care classes for women,she also leads automotiveworkshops, does personaland business coaching andmakes presentations on awide range of automotiveand business topics all overthe country And, Bogirecently entered her secondseason as one of the three-female crew on theVelocity Channel’s “All Girls Garage.”

“As a technician and as a business owner, I’m sionate about educating my customers and the com-

pas-munity as a whole,” Lateinersaid “I love the automotive after-market industry, and I’m com-mitted to continuing to improveour reputation and to making thecar care and repair experienceless scary for everyone, and par-ticularly for women.”

“Bogi’s vision for the tive service industry seeks toempower consumers throughknowledge of automotivebasics,” said Mike Harvey, brandmanager for WIX Filters “Herapproach to consumer education also includes out-reach to women on how they can pursue careers asauto mechanics She represents the future of auto-motive technicians and is an exceptional choice forthis year’s ‘Best Tech’ award.” ■

Bogi and Ray Evernham in front

of the trophy.

Trang 17

Trang 18

Alignment Spec Sponsored by:

years, the

sus-pension did not

The only major alteration

oc-curred in 2009 when the

sus-pension was updated and lost

the built-in adjustments for

front caster and camber

What changed significantly

during the nine-year run was

the role of the steering

posi-tion sensor In 2009, Mazda

made electro-hydraulic power

head-sensor is functioningproperly after an alignment

Front Suspension

The front suspension on theMazda is the same designyou see on many Ford prod-ucts The front knuckle isdesigned with unique scrubradius and steering axis Oninspection of the knuckle, pay

attention to the steering armsand the included angle

On 2004-2009 models, thecamber and caster isadjustable by ±1º by mov-ing the upper strutmount On 2010-2013

models, thereare no adjust-ments orconventionalaftermarketalignmentkits

Mazda

advis-es technicians should look fordamaged parts like the lowerrear control arm bushing.Some shops have had successwith elongating the holes inthe strut tower, but this is notrecommended

It is possible to increaseadjustability by installing a

“high performance upper

Mazda3

Trang 19

BrakeandFrontEnd.com 17

mount, but this will

significant-ly increase noise and vibration

On the MazdaSpeed version,

make sure the caster and camber

are well within cross-tolerances

If not, the torque steer problem

could get even worse

Trang 20

Mazda3 uses Ford’s Control Blade design.

For 2009, the suspension was revampedwith new lower control arms The angles ofthe suspension are influenced by the rideheight of the vehicle to increase stability ofthe vehicle

The toe is adjustable by an eccentricbolt attached to the inner mount-

ing point of the lower

control arm

Make sure thevehicle is loadedwith a full tank offuel or the appro-priate amount ofweight before set-ting the final angles

Camber can bechanged by installingadjustable upper con-trol links Beforeinstalling these parts,check the condition onthe bushings in the lat-eral stabilizer links Ifthese bushings fail or

go soft, they can causenegative camber andtoe The most commonsymptom is inner edge tire wear

Steering Angle Sensor

On 2004 -2008 Mazda3 models, the steering position sensor does

Go to www.bfeRAPIDRESPONSE.com

Alignment Spec

Trang 21

Trang 22

not need to be reprogrammed However, you can observe the output of the sensor with a scan tool Bylooking at the SWA_POS PID, you can see the voltage change positively when the wheel is turned tothe left, and negatively when turned right This type of steering angle is not looking for the exactangle of the wheel, but the amount and rate of steering angle change

On 2010 and newer Mazda3 models, the steering position sensor must be relearned through the OBD

II connection after the toe has been altered 2010 and newer models use this for the electro hydraulicsteering system as well as the stability control

On 2011-2013 models, the steering angle and speed sensors also control the optional adaptive frontlighting or AFS system This system turns the headlights in the direction of the front wheels If thesteering position sensor is not calibrated, the lights will not point at the correct angle

Mazda recommends on 2010-2013 models that after the sensor is recalibrated the technician performsthe following procedure to make sure the steering position sensor is properly calibrated with the key

on and the engine running:

1.Align the steering wheel to the center

2.Within 5 to 10 seconds, turn the steering wheel completely to the right and then completely to theleft, then return to the center

3.Within 1 to 2 seconds, turn the steering wheel completely to the right and then completely to theleft, then return to the center

4.Repeat steps 2 and 3 one more time

5.Verify that not codes are set after a test drive ■

Alignment Spec

Trang 23

Trang 24

Brake Job

Camaro Caliper Conundrum

Some early Camaro owners noticed wheel

weights on their Camaro SS Brembo brake

calipers These weights looked like someone

at the factory was playing a prank, but the

weights were functional and helped to add mass

to the caliper so it could better dampen vibrations

This solution was implemented after careful

evaluation and validation by the Chevrolet

engi-neering team The stick-on weights helped

pre-vent noise under certain driving conditions, but

were not a long-term solution due to the

reduced longevity of the two-sided tape when

applied to a hot brake caliper

The final solution came in the form of weights

on the ears of the brake pad This more

sophisti-cated solution added mass to the pad and

became the factory fix These weights look like

casters and stick out above the caliper housing

By having the extra weight on the pads and not

the caliper, a wider range of brake noises can be

shifted or eliminated when compared to the

weights placed on the caliper

If you are looking for a replacement pad for a

customer who primarily drives on the street,

there are aftermarket pads with these weights on

the pads Some performance pads do not havethese weights The lack of weights will not alterthe design of the system, but the customer mightnotice more noise If the driver is using the vehi-cle for racing, they probably will not complain Ifyou use the updated pads, the wheel weights onthe caliper can be removed ■

HOW A FEW WHEEL WEIGHTS STOPPED BRAKE NOISE.

Trang 25

Trang 26

Driveshafts By Gary Goms

Universal Joint

Inspection & Replacement

In modern automotive

architec-ture, universal joints are most

commonly found on the rear

axles of light trucks, SUVs and

RWD passenger cars While some

low-angle joints are made with a

rubber-compounded material,

most modern universal joints are

made of a steel cross connecting

four trunnions containing

lubricat-ed nelubricat-edle bearings See Photo 1.

Eventually, the needle bearings

wear grooves into the

case-hard-ened surfaces of the cross, which

allows the propeller shaft to

rotate slightly off-center The

rule-of-thumb spec for off-center

rota-tion is generally 0.010” measured

at the end of the propeller shaft

tube In the most catastrophic

cases, the lubricant in the

trun-nion bearings can be lost, which

will cause the joint to separate

Larger universal joints can be

inspected for extreme wear by

twisting the propeller shaft back

and forth Smaller joints can be

tested by prying the trunnions

back and forth with a large

screw-driver Preventive inspections can

be made by watching for rust

for-mations around the trunnion seal

indicating that the trunnion has

lost its lubrication In another

case, the driver might complain of

a snapping or popping sound atlow speed, which might indicatethat the trunnions are seizing due

to lack of lubrication Seizing can

be diagnosed only by removingthe propeller shaft and checkingeach universal joint for smooth

operation by hand See Photo 2.

Because the trunnion bearingsare located at 90-degree intervals,

a conventional universal joint actually accelerates and deceler-ates as it turns

To eliminate this uneven rotatingspeed, universal joints are

installed in pairs and phasedalong the same plane on the pro-peller shaft When the U-joints arecorrectly phased, the propellershaft speed smooths out becauseone U-joint accelerates as its com-panion joint decelerates

Unfortunately, some splined piece truck propeller shafts can beincorrectly phased during

two-reassembly This condition can bedifficult to detect since incorrectphasing often results in a harmonic vibration that resonatesunder different conditions ofspeed and load For this reason,it’s always important to index the

propeller shaft to its matingflanges and to its individual parts before replacing universal joints.Harmonic vibrations can also becaused by universal joints

operating at unequal angles ofdeflection at the propeller shaft.These angles should be measuredwith the vehicle at normal sus-pension height and load In someapplications, the angle at the rearaxle can be adjusted, either withshims or by a control arm eccen-tric, to allow the rear axle piniongear shaft to operate in the sameplane as the transmission See

Photo 3

Using a hand-held universaljoint press will prevent damage tothe propeller shaft, as will soak-ing the joint in penetrating oilbefore removal If required, packthe needle bearings with chassisgrease and always lubricate thepropeller shaft loops before assembly If used, grease zerksshould point toward the propellershaft and be aligned along thesame plane If the U-joint feels toostiff after it has been installed,align the trunnions by tapping thepropeller shaft loops with a medi-um-sized hammer ■

Photo 1

Photo 2

Photo 3

Tiêu đề	Quy trình thiết kế & chế tạo ô tô 12/2013
Thể loại	bài luận
Năm xuất bản	2013
Thành phố	Akron

Định dạng
Số trang	52
Dung lượng	18,48 MB