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Braking system components generally are safety critical products. Commercial vehicles braking systems are of highly safety critical as they pose a serious threat to life and property. Therefore, a system must be designed and validated to minimize the effects of component failure of these portfolios of products. In order to avoid accidents due to brake failures, this paper mainly focuses on analysis of loss of pneumatic fluid pressure in the components of the braking systems. Leakage of pneumatic fluid pressure through the sealing in braking system is one of the major reasons for the failure of the brakes in the vehicles. The aim of the present study is to simulate the lab failure and improve the design using finite element analysis. Also, the optimized design is validated by experimentally. A finite element model is developed in Ansys Workbench to study the behavior of the sealing ring under assembly conditions.

Air Supply Unit (ASU) serves as the pneumatic source for the air suspension system in the passenger car segment. The ASU is an electrically driven oil-free compressor with integrated air dryer to deliver dry air to the suspension system. Solenoid valve, Height Sensor and ECU adjusts the pressure in bellow based on the vehicle load condition. During the lab test, pressure was not building up in the compressor due to delivery valve failure. The type of valve in asu is reed valve type, it is mostly used in the micro compressors due to its low cost, simple structure and light weight configuration. The reed movement is based on the pressure difference between the inlet and the compression chamber. Failure analysis is carried out based on the finite element analysis to identify the root cause, the root cause identified is optimized to prevent the failure.