04014 - fuel injector drip sensor test standedge.rit.edu › edge › oldedge › public ›...
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04014 - Fuel Injector Drip Sensor Test Stand
•Jason Chekansky – Project Manager, ME
•Hugh Campbell – Lead Engineer, ME
•Peter Boyer – ME
•Matthew Kubarek – ME
•Brian Crawford – ME
•Richard Peffer III – EE
•Courtney Stout - IE
•Dr. Alan Nye – Faculty Mentor
•Lee Markle – Delphi Representative
R·I·T Preliminary Design Review
Problem Statement�� Research, design, and implement an Research, design, and implement an
automated fuel injector drip sensing system.automated fuel injector drip sensing system.�� Sensing system to integrate with fuel Sensing system to integrate with fuel
injector control already in use.injector control already in use.�� Design of a test chamber to house the fuel Design of a test chamber to house the fuel
injectors and sensing system.injectors and sensing system.
R·I·T Preliminary Design Review
Current Set-up and Test�� LabVIEWLabVIEW based controlbased control�� Single injector testing capabilitiesSingle injector testing capabilities�� 1010--20 minute tests20 minute tests�� Manual system requires constant Manual system requires constant
user input user input
R·I·T Preliminary Design Review
Process Flow Chart
R·I·T Preliminary Design Review
USER INPUTStart purge cycle.
PROCESSPurge fuel injectors.
VARIABLEDrip falls from injector tip.
PROCESSFuel injector test cycle.
USER INPUTStart test.
DETECTIONSensor system detects
drip.
DAQSignal is amplified,filtered, and sent to
computer.
INTERPRETATIONLabVIEW records
timestamp.
END OF PROCESSTest ends, file saved.
Specifications�� Detection and time stamping of dripsDetection and time stamping of drips�� Sensing function automated after start of testSensing function automated after start of test�� Capability to test 80% of Delphi InjectorsCapability to test 80% of Delphi Injectors�� SetSet--up time < 10 min per injectorup time < 10 min per injector�� Results must be collected in Results must be collected in LabVIEWLabVIEW�� Injectors capable of rotating 0Injectors capable of rotating 0oo to 90to 90oo
�� Test containment unit capable of withstanding full vacuumTest containment unit capable of withstanding full vacuum�� Comply with Delphi standard safety guidelinesComply with Delphi standard safety guidelines�� Payback within 6 monthsPayback within 6 months
R·I·T Preliminary Design Review
Concept Development Work Breakdown
Accelerometer�� Accelerometer detects impulse Accelerometer detects impulse
created by drip created by drip �� Diaphragm testing: Pending data Diaphragm testing: Pending data
analysisanalysis�� Vendor contacts establishedVendor contacts established�� Further experimentation at Delphi Further experimentation at Delphi
scheduled scheduled
ACCELEROMETERDIAPHRAGM
R·I·T Preliminary Design Review
Infrared Detection�� Infrared emitter/detector transistors Infrared emitter/detector transistors
acting as a current switch to detect acting as a current switch to detect photon changesphoton changes
�� Concept proved with common parts Concept proved with common parts assembled on a prototyping boardassembled on a prototyping board
�� Research and testing to optimize Research and testing to optimize components and array configurationcomponents and array configuration
�� Further experimentation at Delphi Further experimentation at Delphi scheduledscheduled
R·I·T Preliminary Design Review
Feasibility�� TechnicalTechnical
�� SetSet--up Timeup Time�� RepairRepair
�� EconomicEconomic�� CostCost
�� ScheduleSchedule�� R & DR & D�� ProgressProgress
�� PerformancePerformance�� LifecycleLifecycle
�� SafetySafety
R·I·T Preliminary Design Review
Sensor System Feasibility Radar Plot
0
1
2Setup Time
Repair
Cost
R & D
Progress
Performance
Life Cycle
Safety
Accelerometer Infrared
Preliminary Design Test EnclosureTest Enclosure
• Polycarbonate viewing window
• Pressure relief system
• Design for full vacuum load
Fuel Injector Standoff
• Provides 90o of rotation
• Fuel injector tip remains at axis of rotation
• Simple screw together set- up
Fuel Injector Adapter
• Multiple lengths to accommodate different styles of injectors
• Fuel rail style attachment
R·I·T Preliminary Design Review
Analysis of Test Enclosure
R·I·T Preliminary Design Review
Preliminary LabVIEW Interface
R·I·T Preliminary Design Review
Cost EstimateAccelerometer Concept: $5010.00Accelerometer Concept: $5010.00
-- Major Components Major Components -- Accelerometers, Signal Conditioner, DAQ, Diaphragms
Infrared Detection Concept: $1730.00Infrared Detection Concept: $1730.00- Major Components Major Components -- Emitters, Detectors, Printed Circuit Board, DAQ
Test Enclosure: $2285.00Test Enclosure: $2285.00-- Major Components Major Components –– Aluminum Test Box, F.I. Fixture, Plumbing, Window,
Gasket Tape, Misc. Hardware
OPTION #1
Complete Accelerometer System:
•Total Price - $7295.00
•Return on Investment - 6 months
OPTION #2
Complete Infrared System:
•Total Price - $4015.00
•Return on Investment - 3.3 months
R·I·T Preliminary Design Review
Schedule for Spring Quarter
R·I·T Preliminary Design Review