Question: help PROBLEM 4 [ 2 0 MARKS ] A critical design challenge has emerged at Proton's powertrain manufacturing facility in Shah Alam, where engineers are
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A critical design challenge has emerged at Proton's powertrain manufacturing facility in Shah Alam, where engineers are developing a new transmission assembly for their nextgeneration compact SUV. The system features an outer hub rotating around a fixed shaft, supported by two tapered roller bearings in a specific configuration. This design is particularly crucial as it needs to withstand Malaysia's tropical climate conditions, including high humidity and temperatures ranging from circmathrmC to circmathrmC while meeting the stringent quality standards of the ASEAN automotive market. The design specifications, aligned with ProtonGeely's quality benchmarks, require continuous operation at rpm with a defined usage pattern of hours daily, days per week. The bearings must maintain their functional integrity for years before replacement, with a reliability requirement of a standard that aligns with Malaysia's National Automotive Policy NAP goals for enhancing local automotive manufacturing capabilities. This operating schedule and reliability target are critical given the growing demand for Malaysianmade vehicles in Southeast Asian markets. The force analysis at MIROS Malaysian Institute of Road Safety Research testing facilities reveals complex loading conditions on both bearings. Bearing A experiences a combination of forces: a tangential force of kN and a radial force of kN The loading on Bearing B is more severe, with tangential and radial forces of kN and kN respectively. Additionally, the system must accommodate a downward thrust force of kN applied by the outer hub, which is critical for maintaining stability during Malaysia's diverse driving conditions, from urban highways to rural roads. The bearing selection process must utilize specifications from DRBHICOM's approved supplier catalogue Manufacturer which provides a K factor for their tapered roller bearings. The design calculations must incorporate an application factor to account for Malaysian road conditions and climate variables. These factors are crucial for meeting the Malaysia Automotive, Robotics and IoT Institute MARii standards for component durability and reliability. The engineering challenge, undertaken by local Malaysian automotive engineers, is selecting appropriately sized tapered roller bearings that can handle the combined loads while adhering to the government's localization requirements under the NAP The solution must consider the technical specifications and factors such as local maintenance capabilities, thermal performance in tropical conditions, and costeffectiveness for the ASEAN market segment.
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