Brian Church, Anthony Salmin, Tyler Breitung, Ross Bluth, Michael Oplinger, Stephen Mroz Week 6 System Level Design Review - 10/2/14
Background o Problem Statement o Customer Requirements o Engineering Requirements o House of Quality Functional Decomposition Concept Development Feasibility Analysis Risk Assessment Test Plan Project Plan Week 6 System Level Design Review - 10/2/14
Dynamic range of flow of 100:1 No means of flow rate control Not ready for use in an automotive environment Week 6 System Level Design Review - 10/2/14
Increase the flow rate accuracy to ± 0.5% A distribution plate for mixing CNG and air Smaller and lighter than current prototype A Proportional-Integral-Derivative (PID) actuator control algorithm to increase flow rate accuracy Week 6 System Level Design Review - 10/2/14
Fully operational prototype that can be tested and verified with compressed air Complete technical design documentation Comprehensive system operation instruction manual Documentation of failure modes Demonstration at Imagine RIT Week 6 System Level Design Review - 10/2/14
Low cost Simple installation Small and lightweight Design for manufacturability Electrical/Mechanical packaging for an automotive environment Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
3 Constraint 1 Constraint Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
mass flow rate control 3 1 Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
(0=Easy to Accomplish, 10=Extremely Week 6 System Level Design Review - 10/2/14 Max Relationship Value in Column Weight / Importance Target of Limit Value Relative Weight Difficulty Difficult) 11.7 187 ± 0.5° Accuracy of position sensor 9 7 122 7.6 ± 5% Repeatability of mass flow rate control 9 8 114 7.1 2 Number of separate assemblies 9 5 110 6.9 6-18V Operating voltage 9 1 110 6.9 Yes Usability with different gaseous fuels 9 3 110 6.9 100 to 1 Dynamic range of flow control 9 2 150 9.4 $100 Cost of production device 9 9 85.1 5.3 80 °C Temperature limit 9 3 52.7 3.3 TBD Manufacturing labor cost 9 89.2 5.6 86.5 cubic inches Size envelope 9 8 48.6 3.1 4 lbs Total weight 9 6 36.5 2.3 50 ms Open/close response time 9 1 36.5 2.3 Vortex Fuel mixing shape 9 4 48.6 3.1 TBD Installation time 9 12.2 0.8 4.7L Compatible engine size 9 2 48.6 3.1 3.1 Operating life 48.6 3.1 3.1 Number of full cycles 4.8 4.8 77 Shock resistance 110 6.9 6.9 Vibration resistance
(0=Easy to Accomplish, 10=Extremely Max Relationship Value in Column Week 6 System Level Design Review - 10/2/14 Weight / Importance Target of Limit Value Relative Weight Difficulty Difficult) 13.8 223 ± 1% Accuracy of mass flow rate control 9 7 145 ± 1% Repeatability of mass flow rate control 9 9 8 72.6 4.5 25 cc/min Leakage rate of device 3 7 131 8.1 6-18V Operating voltage 9 1 131 8.1 Yes Usability with different gaseous fuels 9 3 131 8.1 100 to 1 Dynamic range of flow control 9 2 155 9.6 $100 Cost of production device 9 9 43.5 72.6 72.6 48.4 43.5 14.5 14.5 2.7 2 Number of separate assemblies 9 5 4.5 80 °C Temperature limit 9 3 4.5 86.5 cubic inches Size envelope 9 8 4 lbs Total weight 3 9 6 2.7 50 ms Open/close response time 9 1 0.9 Vortex Fuel mixing shape 9 4 0.9 4.7L Compatible engine size 9 2 58.1 58.1 82.3 3.6 Operating life 9 3.6 Number of full cycles 9 5.1 Shock resistance 9 121 7.5 Vibration resistance 9
Issues o How are we going to allocate the flow rate accuracy and response time between the systems? Actions Taken o Accuracy (± 1%) • 80% Actuator/Valve • 10% A/D converter • 10% Leakage o Response time (50 ms) • 80% Mechanical movement • 20% Computations Current Status o Take allocations into account during detailed design phase Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Week 6 System Level Design Review - 10/2/14
Solution Function 1 2 3 4 5 6 7 1 Provide Input/Output Fitting Barbed Threaded Quick Connect Hose Clamp Compression Welded NONE 2 Measure Temperature Thermocouple Thermistor Resistance Temperature Pyrometer Infrared Thermometer NONE 3 Measure Throttle Position Car Computer Potentiometer Laser Ultrasound Infrared Spring NONE 4 Measure Pressure PC Board Mountable General Purpose Flush Diaphragm NONE 5 Process Signals Microcontroller Analog Processing NONE 6 Measure Current Position Potentiometer Laser Ultrasound Infrared Magnetic Pickup NONE Week 6 System Level Design Review - 10/2/14
Solution Function 1 2 3 4 5 6 7 7 Change Position Cam/Ball Ball Valve Gate Valve Butterfly Valve Rotational Disk Plug Valve NONE 8 Prevent Leaks O-rings Thread Seal Tape Flexseal Gasket NONE 9 Stop Flow In Emergency Spring Loaded Backup Power Counterweight Emergency Sealant Magnet NONE 10 Prevent Overheat Heat Sink Fan Liquid Cool Heat Shield Air Cooling NONE 11 Encase Components Hard Case Magnetic Force Field Soft Case NONE 12 Deliver Fuel Distribution Plate Nozzles Nitrous Delivery NONE Week 6 System Level Design Review - 10/2/14
Concept Function Prototype Modified Prototype Cost Effective High-Tech 1 Provide Input/Output Fitting Four concepts generated Threaded Threaded Hose Clamp Threaded 2 Measure Temperature NONE Thermocouple Thermistor Resistance Temperature o Prototype 3 Measure Throttle Position o Modified Prototype NONE Car Computer Car Computer Car Computer 4 Measure Pressure o Cost Effective NONE General Purpose PC Board Mountable Flush Diaphragm 5 Microcontrollers o High-Tech (Expensive) NONE Microcontroller Microcontroller Microcontroller 6 Measure Current Position Potentiometer Potentiometer Potentiometer Laser 7 Change Position Rotational Disk Cam/Ball Ball Valve Cam/Ball 8 Prevent Leaks O-rings O-rings O-rings O-rings 9 Stop Flow In Emergency Spring Load Spring Loaded NONE Backup Power 10 Prevent Overheat NONE Heat Sink NONE Liquid cool 11 Encase Components Hard Case Hard case Soft Case Magnetic Force Field Week 6 System Level Design Review - 10/2/14 12 Deliver Fuel NONE Distribution Plate Nozzles Distribution Plate
Concept Selection Criteria Prototype Modified Prototype Cost Effective Hi-tech Cost - - - Size 0 0 - Flow Rate Accuracy + + + Flow Rate Repeatability D + + + High Temp Resistance a + - + Design Complexity t - - - Sum + 's u 3 2 3 m Sum 0's 1 1 0 Sum -'s 2 3 3 Net Score 1 -1 0 Rank 1 3 2 Week 6 System Level Design Review - 10/2/14
Concept Selection Criteria Prototype Modified Prototype Cost Effective Hi-tech Cost + + - Size 0 0 - Flow Rate Accuracy - - 0 Flow Rate Repeatability D - - 0 High Temp Resistance a - - + Design Complexity t + + - u Sum + 's 2 2 1 m Sum 0's 1 1 2 Sum -'s 3 3 3 Net Score -1 -1 -2 Rank 1 1 2 Week 6 System Level Design Review - 10/2/14
Concept Selection Criteria Prototype Modified Prototype Cost Effective Hi-tech Cost + - - Size 0 - - Flow Rate Accuracy - + + Flow Rate Repeatability D - + + High Temp Resistance a 0 + + Design Complexity t + - - Sum + 's u 2 3 3 m Sum 0's 2 0 0 Sum -'s 2 3 3 Net Score 0 0 0 Rank 1 1 1 Week 6 System Level Design Review - 10/2/14
Concept Selection Criteria Prototype Modified Prototype Cost Effective Hi-tech Cost + + + Size + + + Flow Rate Accuracy - 0 - Flow Rate Repeatability D - 0 - High Temp Resistance a - - - Design Complexity t + + + Sum + 's u 3 3 3 m Sum 0's 0 2 0 Sum -'s 3 1 3 Net Score 0 2 0 Rank 2 1 2 Week 6 System Level Design Review - 10/2/14
Optimized Prototype The Modified Prototype was ranked Threaded 1 st in the Pugh Evaluation Thermocouple Thermistor However, we still have to evaluate Car Computer several component alternatives General Purpose PC Board Mountable to meet the accuracy and cost Microcontroller deliverables Potentiometer Cam/Ball Rotating Disk O-rings Spring Loaded Heat Sink NONE Hard case Week 6 System Level Design Review - 10/2/14 Distribution Plate
Question: Will the valve design have an impact on the flow rate accuracy? o Ball valve • Needs to be designed from scratch, low accuracy o Gate valve • Needs to be designed from scratch, low accuracy o Cam/ball • Already implemented in a prototype, high accuracy o Rotating disk • Already implemented in a prototype, high accuracy Week 6 System Level Design Review - 10/2/14
Question: Will the valve design have an impact on the flow rate accuracy? o Cam/ball • Snail • Egg • Dwell Snail Egg Dwell Week 6 System Level Design Review - 10/2/14
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