Background & Guidelines
- A Clinched Joint is defined as a pipe with o-ring, inserted into the neckshell of a heater core; this assembly is then entered into a fixture to hold the core as the jaws on a cam plate roll to deform the neckshell onto the bead of the pipe. The deformation of metal causes a gap between the pipe O.D. and the clinch – a maximum of 2mm gap is allowed.
- With this methods, the joint is then tested for leaks on the same equipment that performs the clinch operation. The maximum leak rate is 6 cc/min air.
- The Production team is concerned that our current type of leak test may not accurately correlate to life time integrity of the compression portion of the joint.
- Delphi Thermal & Interior is designing and Validating the components as well as the final assembly.
- We need to find a NON-DESTRUCTIVE way of verifying joint integrity in a production environment.
- Must be applicable to the HC-340 and all heater core assemblies.
- Delphi Thermal & Interior must review all presentations to RIT or any non-Delphi personnel prior to presentation for clearance of Record of Inventions.
- Integrate this Non-destructive test within planned assembly/test process. For example: Leak Test and Clinch Joint Assembly Process.
- Production Volume = XXXX Heater Cores per 8 hour day per 1 piece of equipment. The typical cycle time in production assembly is 19-20 sec for clinch and test operation.
- Must be ergonomically acceptable for the operator.
- Must be environmentally friendly for the operator.
- Must meet operator Safety requirements
- Cost of Equipment must not exceed $_75,000
- Must not adversely effect performance of joint or heater core assembly for use by the customer for the life of the product.
- Must be in production no later than: 1) Proof of concept supplied by April 2005 2) Provide a list of outside contacts for test equipment Assist with development or recording of specifications for joint and equipment. This will be in a workshop type environment on site with Delphi T& I engineers
- Functional Prototype of equipment
- MSA (Measurement Systems Analysis) on Equipment
- Design guidelines for future equipment.
- Design Development Memos (DDM’s) recording development activities and lessons learned.
- Statistical proof of correlation to design validation testing.
- Estimate of production cost, timing & list of equipment suppliers and contacts.
- Formal presentation to Delphi Thermal & Interior management ( specifically the Heater Core Clinch Team)
- Monthly Update of progress with KTM tracking
- I&CIM methodologies (TMAP, PMAP etc – These templates will be provided by Delphi if RIT is not familiar)