Failure analysis of an off-road vehicle in SAE Brasil university competitions: a study of the suspension system using failure mode and effect analysis and fault tree techniques

Abstract

Highlights: FTA is a reliability technique aimed at identifying all the combinations of causes that can give rise to an undesired event, studying the probability of these causes occurring, and prioritizing actions to prevent these causes from happening and resulting in the undesired event. The method allows the analysis of system reliability and the construction of the cause-and-effect relationship of its events, creating an interface with the FMEA tool. FMEA is a reliability tool used to find possible failures in a system and assess their possible consequences. These methods and techniques seek to improve the reliability of products or processes, i.e., increase the likelihood of an item performing its function flawlessly. Aim: This paper will analyze failures in the suspension system of an SAE competition off-road vehicle using fault mode and effect analysis (FMEA) and fault tree analysis (FTA) techniques with a view to improving the performance of these vehicles in future competitions. Design/Methodology/Approach: The researchers began by defining the suspension system as the object of study with the racing team, followed by collecting information and failure data on this system. The FMEA and FTA tools were then used alongside interviews with the racing team. Results: The analysis of the results showed that the two highest probabilities of failure are related to the suspension and the axle sleeve, with values of 38.8% and 20.5%, respectively, and that the rotary terminal is the most critical element. Research limitations: The limitations of this research include the subjectivity of assigning FMEA scores due to the team's lack of experience and the limited history of documenting data on vehicle failures related to the dynamics of SAE competitions. Practical implications: The practical implications of this study include the possibility of professional improvement for the engineering students belonging to the competition team. Originality/value: The literature search revealed that the research topic is original and challenging at the same time. Its results will allow us to re-evaluate the construction project for the Baja competition vehicle.

Keywords: FMEA; FTA, Baja SAE Brazil Program; Suspension System.