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