Missing Spray Holes in HPI HD Injector Nozzles

Sponsored by: Cummins, Inc.ME 462 Capstone Design – Spring 2008

Design Team: David Graves, Aaron Huesman, Kelly McCormick, Brandon Underwood

Advisor: Dr. H. A. El-Mounayri

Reason for Design

• HPI HD Injector Nozzles• Partial or Missing Spray Holes

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Main Requirements and Targets

• Implement non-contact method of checking nozzles for correct number of thru holes.

• Keep up with current production rates (3900 nozzles per day maximum.)

• Identify nozzle part number (ID matrix read)• Pass/Reject nozzle before next manufacturing

operation.• Keep current manufacturing process

cleanliness (4 micron tolerance).Purdue School of Engineering and

Technology 3

Product Presentation

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Insert Nozzle Here

Matrix Reader Gets Part Number

Part Number Sent to AutoID

Controller

AutoID Controller Sends Program # to Vision System

Part is either “OK” or “NG”

“NG” Parts are Rejected

Product Evaluation(Engineering Targets)

• Residue size under 1 µm: None Expected• Footprint under 1 foot2: Within Range• # of Operators Needed 1 or less: 1• # of Operator Miscues <=1 / 100: None with

minimal training.• Less than 2 hours of maintenance per month:

Met• Steps required to use <=2: Within Range• Time added to process <=10 sec.: Under

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Product Evaluation(Engineering Targets)

• Minimize cost added: $0.012 per nozzle over the first year.

• Number of injuries per year, zero: None expected.

• % of nozzles damaged during process, zero: None expected.

• % of incorrect identification or pass/fail, zero: None Expected.

• % of models capable of being tested, 100: Inconclusive but positive indications.

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Conclusions and Recommendations

• Conclusions– Test unit meets all customer requirements set

forth in the design phase– Test unit meets or exceeds all engineering targets.

• Recommendations– Automate by incorporating into assembly line– Develop case to house electrical control

components– Reinforce test unit housing with stiffening agents

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Questions/Comments

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