group m1.2 - intertek senior design groupbcad124e-4e... · group m1.2 - intertek senior design...

Problem ProcessProposed Solution

Group M1.2 - Intertek Senior Design GroupProject Manager: Zane Gooden

Group Members: Dieudonne Dusingizimama, Luis Ortiz, Brandon SekulaSponsored by Intertek Automotive Research

We are working on optimization of Intertek’s chain wear test build for the 4‐cylinder Ford Eco‐Boost engine

Currently the process is not fully optimized

Focused on reducing build time, part rework, and maintaining build quality

Current fixes include: ball hone method fix, oil filter housing jig, valve spring compressor attachment, engine timing tool, and valvetrain organizer

L

Cross section of a cylinder (A) and Ball Hone drill speed (S)D

ConceptualizationCustomer needs: Reduce build time Maintain test accuracy Reduce part rework Reduce overall cost, if 

applicableInitial Ideas: Oil Filter Housing Jig Valve Spring Compressor 

Attachment Workspace Organization Ball Hone Method Fix Engine Timing Tool Application of RTV Fix Main Bearing installation jig

A= 2tan‐1   Reciprocating SpeedRotational Speed

Reciprocating Speed = tan (A/2) * Rotational Speed

Current Work Prototyping our designs Improving the design 

prototypes to verify functionality

Re‐prototyping until design satisfies its requirements

Current Work Manufacture and assemble 

our fixes Test fixes inside the process Continually improve them 

until they are exceptional

Valvetrain assembly organizer Oil filter housing jig

Valve Spring Compressor attachment

Engine Timing Tool

Ball Hone method fix

Compresses two vales instead of the single valve currently

Organizes the valvetrain assembly to reduce messes

Times the engine without removing the oil pump while on test stand

Jig to align the oil filter to allow a hole to be drilled to insert a thermocouple to test oil temperature

Create a method to standardize the ball hone process with a metronome