10/30 Update

This Week:

• Throttle Body Elbow DOE
• Coil Bracket and misc. small parts design
• Finalizing dimensions

Next Week:

• Final drawings for most to all parts
• New Gantt chart for November
• Scheduling for manufacture

Throttle Body Intake DOE

Problem Statement

• A DOE (Design of Experiment) was done on the throttle body intake.  
• Three different designs were used as initial runs (Low Intake Elbow, High Flow Intake Elbow, Box Intake Elbow)
• Two variables were altered for this experiment; throttle body flange angle and spline gap.

• The max velocity at the outtake was used as the main result in deciding which design proved to be best.

Results

The top three designs were selected...

3847_splinegap_1

3848_splinegap_2

3847

Conclusion

• Throttle body flange angle and spline gap were the two main variables that could alter the max velocity at the exit.  
• Of the two, changing the spline gap yielded the highest max velocity.  
• Further design will be done when final measurements are taken at throttle body.

Throttle Body Flow Analysis

Throttle Body Elbow

10/23 Update

This Week:

• Throttle body elbow modeled
• Flow analysis for throttle body elbow
• Started drawing for reluctor wheel mount/crank sensor mount

Next week:

• More flow analysis for throttle body elbow
• Pick final design for throttle body elbow
• Model ignition coil brackets
• Drawings for modeled parts

Weekend Junkyard Run

This weekend the group went out for a junkyard run.  We ended up going to three different junkyards looking for cooling fans and an adequate fuse box.  

Crank Sensor Mount

New Reluctor Wheel Mount Design

10/16 Update

This Week:

• Junkyard runs
• New design for reluctor wheel mount modeled
• Crank sensor mount modeled
• Throttle body elbow design started

Next Week:

• Model throttle body elbow
• Flow analysis for throttle body elbow
• Spring design for crank sensor mount
• Drawings for reluctor wheel mount and crank sensor mount

10/9 Update

This Week:
First revision for PCM bracket Mount
CAD work for Reluctor Wheel Mount
Design/CAD work for crankshaft sensor mount
Began design work for throttle body elbow

Next week:
Random Vib analysis for PCM bracket, reluctor wheel mount
Finalize materials for PCM bracket, Reluctor wheel mount
Finish CAD work for crankshaft sensor mount
Begin CAD design for throttle body elbow
Begin drawing for Reluctor wheel mount

Updated October Gantt Chart

October Gantt Chart Revision 1 Changes

Added vibration analysis to be done on Throttle Body, Crankshaft Mount, and Reluctor Wheel Mount.

Note:  Some end dates end sooner than listed on chart (Weekends are not considered work days on Gantt Project)

Reluctor Wheel Mount

October Gantt Chart

Rough schedule for the Month of October.  If all goes according to plan, we can begin manufacturing parts by the third week of October.

Wire Harness Stripped Down / Reluctor Wheel Drawing

Over this past weekend, the team met to strip down the wire harness.  This involved removing all the tubing/tape, as well as removing all unnecessary wires that would not be needed for the final wiring.

In addition, the team drew some rough sketch ideas for the reluctor wheel mount sensor design.

PCM Bracket drawing

10/2 Update

This week:

• PCM Bracket Drawing
• Began Bracket material selection
• CAD work for Reluctor Wheel Mount
• Design work for Crankshaft Sensor Mount
• Gantt chart for October
• Got together for wiring harness modification

Next week:

• Obtain material for PCM bracket
• Finalize PCM bracket drawing
• Finish Reluctor Wheel mount CAD
• Begin Crankshaft Sensor CAD work
• Junkyard run on Saturday
• Begin Throttle body elbow design work