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Fuel Tank Design and Production Testing |
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When dealing with fuel tanks, safety is of the utmost of priority. Brown Davis goes to extraordinary lengths to ensure that the structural rigidity, and production quality of each tank not only meets, but surpasses all current regulations surrounding fuel tanks and impact protection.
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A critical aspect of design is to ensure the tank is structurally strong enough to withstand large impact forces. With a current ADR fuel tank test licence, Brown Davis is able to carry out specific, yet brutal testing of new tank designs. Current test procedures include a drop test with a fully laden tank from a specified height of 9m (30ft). During this test the tank must not show any signs of splitting or potential hazard upon impact. With such testing and data acquisition, each new tank design incorporates vast experience in structural design knowledge to ensure designs not only to exceed civilian vehicle safety standards, but those of many worldwide armed forces currently using Brown Davis tanks out in the battle field.
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During production, a different form of testing is also carried out. As another critical stage of the fuel tank manufacturing process, ensuring that each tank is perfectly sealed and leak free is paramount. As with any form of welding, there is a chance of porosity in a weld seam, which even though mostly invisible to the naked eye, can leak and pose a potential safety hazard. It is for this reason that Brown Davis incorporate several leak tests in order to ensure each tank is 100% leak free prior to leaving the Brown Davis facility.
With the tank sealed and pressurised to a set level, a preliminary test is carried out as an early leak detection measure on all weld seams. This involves painting the seams with a soap based mixture which reveals bubbles at leak locations. Upon completion of this test, the tank is then fully submerged in a testing tank, and again under a set pressure level, will indicate even the most minute of air leaks via bubbles in the water.
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Brown Davis Automotive was established in 1978 in Melbourne Australia, by Managing Director David Brown. David is still actively involved in all facets of design and manufacture in the company, and with his university engineering background has consulted on the CAMS motorsport technical panel, and several other government and military bodies. From small beginnings, Brown Davis has grown to become one of the leading manufacturers of aftermarket fuel tanks and ROPS in the world today. The initial focus of Brown Davis was motorsport in Australia designing and manufacturing light weight alloy fuel tanks and safety roll cage structures for racing cars. Stemming from this, came an ability to fabricate in many of the more exotic materials and the engineering ingenuity that supported many Australian and international motorsport champions.
The Brown Davis long range and auxiliary fuel tank range is an engineered solution for being able to travel further with less fuel stops. They are designed to give maximum fuel capacity without affecting ground clearance and ramp over/departure angle, whilst being exceptionally strong against the most rigorous of conditions. The Brown Davis long range and auxiliary tanks allow you to get to the most remote parts of the globe where standard tank wouldn't take you, or as a tradesman get to that extra jobsite without constantly needing to stop for fuel.
All Brown Davis long range and auxiliary fuel tanks are constructed from high grade 2mm 14 gauge - Aluminium coated cold rolled steel, to ensure maximum strength and durability. This gauge of steel is sufficiently resistant to damage by impact, and therefore additional tank guards are not necessary (most standard tanks are less than 2mm in material thickness). This material is specifically imported by Brown Davis based on critical specifications. Unlike aluminium, steel is not prone to fatigue from vibration and twisting as seen in off road conditions. This fatigue resistance far outweighs any weight advantage aluminium may offer. However, the aluminium coating on the specific steel used by Brown Davis, offer's the strength of steel with the anti corrosion properties of aluminium.
The Brown Davis manufacturing facility houses some of the latest state of the art equipment including, computerised cutting equipment, folders and welders to name a few. Brown Davis also takes full advantage of the latest in 3D CAD modeling software, to model tanks and components prior to manufacture. Thus, giving a distinct design advantage when it comes to prototyping and producing a new tank.
The Brown Davis long range and auxiliary fuel tanks are arguably the most thoroughly engineered long range and auxiliary tank on the market. Some design elements include internal tank baffles to prevent fuel surge when travelling on unstable terrain, double skinned faces behind mounting bracket surfaces, and magnetic drain plugs fitted horizontally to prevent tank damage in the event of the tank coming into contact with terrain beneath the vehicle, just to name a few.
A Roll Over Protection Structure (ROPS) is a reinforcement member(s) installed in to, or on to a vehicle with the intention of protecting the vehicles occupants in the event of a roll over accident.
The primary intent of a ROPS is to limit the crushing and deformation of the vehicle roof and cabin structure during a roll over accident. This ensures that the vehicle occupants are provided with an adequate amount of survival space which reduces the risk of head, neck/spinal, and upper torso injuries, ultimately preventing death.
All Brown Davis ROPS kits are designed as bolt in systems to suit individual vehicles. All components are carefully prototyped on a test vehicle to ensure critical tolerances are achieved for a neat fit and optimum protection. Ensuring maximum occupant space is obtained, and entry/exit considerations are maximised, is paramount in each design. Below are some of the key design features of each Brown Davis ROPS unit.
Footplates/Brackets/Backup Plates: Computerised laser cutting and folding of all foot plates, brackets and back up plates ensures perfect jig and vehicle fitment, allowing Brown Davis to consistently replicate each ROPS with tight tolerances. Folding to stiffen all mounting plates is part of the engineering thoroughness of Brown Davis ROPS designs.
Off road touring is fraught with potential hazards that ultimately leave travellers stranded in remote, hard to reach locations. Those who have suffered the mercilous wrath of the outback's rugged terrain, will know first hand just how serious an issue it really is. A punctured sump, a tailshaft jammed with logs, or even a damaged radiator; a failure of this nature can be both very costly and terrifying for those unlucky enough to be stranded without help.
Brown Davis have tackled the issue of Underbody protection head on, to develope bullet proof armour for the underside of most popular off road machines. With over 30 years off road experience, and a solid understanding of what is encountered when off road trekking, Brown Davis has every base of design covered to ensure you have every chance of battling the outback and winning every time. By incorporating specific design features and utilising high grade materials, the Brown Davis Range of Underguards will protect you and your vehicle.
Laser cut on high tech machinery, each guard is manufacturd from 3mm aluminised steel specially imported by Brown Davis, according to stringent specifications, with circular venting holes being protected from protrusion by 3mm steel mesh. The guards are welded to Australian Standard AS - 1554. All guards come with full fitting kits where applicable, (if factory mounting bolts cannot be retained) and comprise of high tensile grade 8.8 fasteners for a true bolt on item.
The Brown Davis manufacturing facility houses some of the latest state of the art equipment including, computerised cutting equipment, folders and welders to name a few. Brown Davis also takes full advantage of the latest in 3D CAD modeling software, to model tanks and components prior to manufacture. Thus, giving a distinct design advantage when it comes to prototyping and producing a new guard, delivering a far superior product.
