Table of Contents
Fuel injection nozzles are tested by being attached to a holder and having pressurized oil sprayed through them. The current process is manual and involves an operator choosing the correct oil pressure and duration of spray, making the process prone to error. An enclosed test fixture was developed to make this process safer and easier for the operator and less wasteful of oil. The system is hard wired for a specific pressure and duration of oil spray.
The project goal is to modify the current system to make it adaptable to different nozzle types. The desired system involves the operator entering the part number through computer controls, and the system automatically choosing the correct oil pressure and spray duration based on preset values. Ideally, the system will automatically bag the nozzle once the test is complete. The end result will be a universal nozzle tester and bagger. The fixture should maintain the same footprint as the current system but be made mobile. In addition, the skill level of the operator must remain the same. The system must not leak and must continue to be safe. The project must be completed within a budget of $10,000.
Use CasesThis section is designed so that the team will identify the different scenarios in which the AA Tech Oil System will be used. This is a step that will help set bounds on specifications and requirements. To view the P16680 Use Scenario LIVE document, click here.
Project Goals and Key Deliverables
- Production ready oil system
- Automated pressure and duration spray setpoints
- Training documentation on the controls
Customer Requirements (Needs)
PurposeAs given by the customer, our task is to design and fabricate an enclosure system that allows varying nozzles to be secured and sprayed with pressurized oil determined by programmed cycle parameters. By organizing the list of system requirements given in our PRP and from our customer interview, we are able to determine exactly what the customer is hoping to see in the outcome of our project, and the priority of each aspect. Customer Requirements Chart
Link to the live document here
Engineering Requirements (Metrics & Specifications)
- To view LIVE Engineering Requirements, click here.
- Power shall be sized for all applications and may be 110Vor 480V.
- The system shall be portable.
- Acrylic chamber should be housed in a par-frame structure. AA Tech will assist with procurement of par-frame ( approx. 4 weeks lead time).
- The test chamber will be designed by team and reviewed with AA Tech. Then AA Tech will assist with procurement (lead time is typically 2-3 weeks).
- Should be useable by an entry level operator
- Total budget shall be $10,000, excluding the cost of the acrylic test chamber and par-frame to be supplied by AA Tech.
- Preservation oil used to flush parts will be supplied by AA Tech (Reference Specification MIL-PRF-6081)
- Use of an Allen Bradly PLC to remain consistent with other PLCs within the facility.
- Quick and easy change over to different part numbers
- Automate bleeding to prevent operator getting sprayed
- Utilize existing programmed pressure and duration set points for oil flow
- Capture excess oil for recycling
House of QualityThe house of quality is used to ensure that all of the customer requirements are met with all of the engineering requirements. This team's house of quality is used more as a visual tool to check that all requirements given by AA Tech are observed. To view the LIVE document for this team's house of quality, click here.
Problem Definition Review
- Link to Problem Definition Review Presentation here.
- Link to Problem Definition Review Peer Review Group Suggestions here.
Problem Definition Review Feedback
- If we want to recommend a PLC, AATech will help us procure it.
- Include customer tasks and status in future presentations
- Go over new action items for the team & customer at the end of the presentation
- Complete the presentation a week before it's due and practice it with your guide
- Add detail to use scenario
- Add legends to all charts that require a scale
- Update risks to include loudness and robustness
- Give high severity to risks that could stop us from meeting a customer requirement
- Prep for peer reviews by Tuesday 9/15
- Meet with Dave Thursday 9/17 to pick up rest of the sample nozzles, tooling, scanner, software, and cables for the PLC
- Get size of oil reservoir requirements from AATech