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The efforts of the ISO “Test Variability Task Force” have been aimed at improving the understanding and at reducing brake dynamometer test variability during performance testing. In addition, dynamometer test results have been compared and correlated to vehicle testing. Even though there is already a vast amount of anecdotal evidence confirming the fact that different procedures generate different friction coefficients on the same brake corner, the availability of supporting data to the industry has been elusive up to this point. To overcome this issue, this paper focuses on assessing friction levels, friction coefficient sensitivity, and repeatability under ECE, GB, ISO, JASO, and SAE laboratory friction evaluation tests.

Riveting is a process used to fasten printed circuit board to housing that offers several advantages compared to screws. This involves a cylindrical pin that protrudes from the housing being compressed with a concave tool to produce a rivet head that fills the PCB hole and holds it in place over service life of the component. The process as performed currently in-house uses parameters that have not been optimized. Testing has revealed that the process is subjecting the PCB to surface strains higher than 1000μɛ which is the limit as recommended by standards. Exceeding this limit reduces the reliability of electrical components and increases risk of field failures. This risk can be mitigated by improving the riveting process parameters to prevent high strain from reaching components. Having a finite element model for high deformation problems is an essential prerequisite to explore riveting process improvement.