Group 14 - Kerosene Heater

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Kerosene Heater


Contents

Group Members

  • Nate Mayers - Group Leader/Communication Liaison
  • Philip Odonkor - Mechanical Expert
  • Eric Nowicki - Product Manager
  • Matt Pfender - Technical Expert
  • Mitchell Slomowicz - Primary Wiki Coordinator

Executive Summary

The objective of this project is to dismantling a high powered portable Kerosene heater in an effort of gaining a broader and in-depth understanding of how it was designed and manufactured, as well as grasp the logic behind its inner workings. It will also provide the team with a hands-on perspective of the assembly process involved in manufacturing the Kerosene heater.

The entire dismantling process will be captured in key stages through recordings, sketches and photographs to show how the different parts relate to each other. Effort would then be taken to name and catalog all the removed parts and fixings.

Introduction

Before dissecting the Kerosene Heater, we were appointed to write an Initial Product Assessment, a Work Proposal, and a Management proposal. The initial product assessment is a report of how we believed the heater works, the energy conversion, materials we believe the product is made of, alternatives to the product, as well as pieces of information such as complexity and components. The work proposal is a report of what we believed we would need to do in order to dissect the heater, the tools we believed we would need, the plan we think we would take to disassembling the heater, time management of the project, as well as the attributes of the group members. The management proposal was the plan we were going to take in organizing the group in a fashion to best suit our needs to achieve a finished report and project. All of these reports are linked in the following pages.

Gate 1 - Pre-Dissection

Initial Product Assessment - Group 14 - 2009

Work Proposal - Group 14 - 2009

Management Proposal - Group 14 - 2009

Gantt Chart - Group 14 - 2009

Gate 2 - Dissection

Upon completion of the product dis-assembly, group 14 reviewed the initial work and management proposals. The intention of this was to assess the group's overall productivity and analyze any changes and challenges faced in the actual product dissection.

Revision to Proposals

Causes for Corrective Action

Group 14’s work and management proposals worked relatively well. The only problems encountered were minor, and easily corrected. The plan worked well because a generous amount of time and consideration went into each part to ensure that the dis-assembly went smoothly.


Work Proposal Corrections:

It was estimated in group 14’s work proposal that roughly 5 tools would be needed to disassemble the heater. The tools specified in the initial work proposal were as follows:

  • Phillips head screwdriver (Size 3)
  • Phillips head screwdrivers (Size1-5) for inner components
  • 3/8” Ratchet
  • Heat Gun
  • Pliers (Regular/Needle Nose)


When disassembling the product we only needed 2 tools. Therefore the tool list in the work proposal could be changed to:

  • Phillips head screwdriver (Size 3)
  • Flat head screwdriver (Size 4)


This overestimation in the initial proposal was caused by group 14’s overestimation of the complexity, and amount of parts in the heater.

Group 14 also overestimated the amount of time it would take to disassemble their product. In the work proposal it states, “the projected time to disassemble this product is approximately 5 hours”. The actual dis-assembly took only one and a half hours. This overestimation was caused by two main factors. The first was an overestimation of the overall complexity of the product. The second was time, which was added to our initial estimation to account for any unforeseen difficulties in the dis-assembly process.

Differences in Proposed Procedure vs Actual Procedure

As far as the steps initially proposed to take the product apart in the work proposal, our actual procedure consisted of the same procedure; however, with more specific details. Although the original proposed steps were out of order compared to our actual procedure, order in this case, did not play a major part. This was because after the fan cover and top heater cover was removed, each individual component was accessible and easy to remove, allowing us to pick the order. As far as changes in detail, the work proposal procedure was generalized to the major steps, where as the actual procedure included the intermediate steps such as removing the screws themselves.


Management Proposal Corrections:

In their management proposal group 14 stated “convenient meeting times will be Monday, Wednesday, and Friday at 5:00 PM” and “the group will meet about once a week when all group members are available”. However, due to heavy workload from other courses, as well as exams, which took place during the product disassembly time period, group 14 was forced to alter their meeting times, and frequencies to accommodate for all group members. These parts of the management proposal could be changed to include weekend meetings, and multiple meetings in one week allowing for the successful completion of each phase in the time frame specified on the Gantt chart.


Unresolved Difficulties:

Group 14’s only unresolved difficulty is the need for one group member to learn CAD/3D modeling before gate 3. They plan on resolving this problem by selecting one of the members to obtain, and become proficient in a 3D modeling software.

Potential Problems for the Next Gate:

The prospect of heavy workloads in upcoming weeks is a continual potential problem, which is difficult to resolve. If the situation arises group 14 will work diligently to free time up to be used on their project.

Learning a 3D modeling software is a potential problem which could be encountered in the future. This will be resolved by the rest of the group assisting in the learning process

Conflict Resolution

In order to solve conflicts that we will face, we will come together as a group the discuss the opposing views, evaluating the pros/cons of each, and coming to a group decision that will benefit the group's work and project the most.

Product Dissection Plan

Ease of Dis-assembly of the Product

Overall, the Kerosene heater was fairly easy to take apart. Each piece was easily accessible and easily removed from the product. Although we do not believe that the product was intended to be taken apart, it was still easy to do so. Based on this observation, we may be able to draw a conclusion that since it was easily taken apart, it was easily manufactured. This would result in more productivity of the manufacturer and possibly increased profit.


As far as the fasteners used, the heater utilized screws of the same size throughout the product with only minor differences in the head of the screws. This make the assembly/dis-assembly process easier, as only 1 tool is needed to put the product together. Screws also provide a means of holding pieces together with the ability to remove them if needed. This makes maintenance easy to complete on this product. The product also featured pieces also fastened by welds on the tank. This was to reduce the chance of leaks as well as ensure the strength.


The scale of ease of this chart is on a range from 1 to 5, with 5 being the most difficult. A rating of 1 can be comparable to a task that can be completed on your first try, where as a rating of 5 may require multiple attempts to complete.


Step # Process Difficulty Tool Needed Visual
1 Removed inner fan fencing guard 1 By Hand 14fencing.JPG
2 Remove top heater cover screws (6) 1 #3 Phillips Screwdriver 14screws.JPG
3 Remove top heater cover 1 By hand 14heatercover.JPG
4 Removed control panel cover screws (4)
  • (Note: this was done twice as there was a panel on each side)
1 #3 Phillips Screwdriver 14screws.JPG
5 Remove control panel covers (2) 1 By hand 14controlcover.JPG
6 Disconnect all wires running to circuit board (5 sets of wires disconnected) 1 By hand 14circuitwires.JPG
7 Remove circuit board screws (2) 1 #3 Phillips Screwdriver 14screws.JPG
8 Remove circuit board 1 By hand 14circuitboard.JPG
9 Disconnect fuel lines from injector system (2 - Fuel Feed and Return) 1 By hand 14Fueltube.JPG
10 Remove screws from fuel injector component(4) 2 #3 Phillips screwdriver 14screws.JPG
11 Remove fuel injector 1 By hand 14injector.JPG
12 Remove screws securing inner heater cylinder (4) 1 #3 Phillips screwdriver 14screws.JPG
13 Remove inner heater cylinder 1 By hand 14innertube.JPG
14 Remove screws on inner heater cylinder (6) 1 #3 Phillips screwdriver 14screws.JPG
15 Remove inner heat exhaust cylinder 1 By hand 14exhaust.JPG
16 Remove electric motor screws (4) 1 #3 Phillips screwdriver 14screws.JPG
17 Remove screws securing ground wires to inner components (2) 1 #3 Phillips screwdriver 14screws.JPG
18 Disconnected electrical wires to motor *** (Disconnected 3 wires) 1 By hand 14wires.JPG
19 Remove electric motor and fan 1 By hand 14motor.JPG
20 Remove Temperature Gauge Bracket from Bottom Heater Cover (Top) 1 #3 Phillips screwdriver
  • (2 Screws)
14bracket.JPG
21 Remove bottom heater cover 1 By Hand 14bottomcover.JPG
22 Remove Ignitor Power Source 1 By Hand 14pump.JPG
23 Remove Pressure Gauge Bracket from Inner Heat Exhaust Cylinder Plate (Bottom) 2 #3 Phillips screwdriver
  • (2 Screws)
14bracket.JPG
24 Remove Ignitor from Fuel Injector 1 #3 Phillips screwdriver
  • (1 Screw)
14ignitor.JPG
25 Remove Inner Heat Exhaust Cylinder Plate 1 #3 Phillips screwdriver
  • (2 Screws)
14heatplate.JPG
26 Remove heater frame handle 1 #3 Phillips screwdriver 14handle.JPG

*** NOTE: Picture for step 16 was taken from Google Images (specifically here) for the reason that the wires in our product were wound in a bundle to the point where a clear picture could not be taken.

Gate 3 - Coordination Review

For Gate 3, Group 14 cataloged each component, as well as, the manufacturing process used to make the component By completing this task, a greater understanding of how the heater worked was achieved.

Component List

Note: the complexity scale in the following chart is has a range from 1 to 5, with 5 being the most complex. For clarification, 1 would be a simple 1 process manufacturing procedure, while a 5 would have multiple processes and be more difficult to manufacture.


Part Function Material Manufacturing Process Complexity Other Information Picture
Inner Heat Exhaust Cylinder Contain heater flame and radiate the heat produced Hot Rolled Steel Hot Rolling
  • Shows discoloration
  • Has cylindrical shape
1 *Was Hot Rolled due to its final shape, a cylinder, which is easy to obtain with this process. 14exhaust.JPG
Inner Heat Exhaust Cylinder Plate Direct airflow to the flame inside Steel Sand Casting, Drilling
  • Grainy surface finish
  • Drill holes
2 *Manufactured like this to produce specific shape without worry to surface finish
  • Holds Ignitor in place
14heatplate.JPG
Inner Heater Cylinder Direct flow over Inner Heat Exhaust Cylinder, and act as a heat dissipation apparatus. Cold Rolled Steel Cold Rolling
  • No discoloration
  • Cylindrical shape
1 *Cold rolled due to shape
  • Attaches to Bottom Heater Cover
14innertube.JPG
Fuel Injector Injects fuel into the Inner Heat Exhaust Cylinder Sheet Steel Pressed and Bent
  • No mold lines
  • Made of sheet steel
2 *Manufactured like this for ease of production, 1 sheet of steel make primary shape, then it is bent to final shape for specific purpose
  • Blades are pitched to direct airflow
14injector.JPG
Ignitor Ignites fuel Plastic and Steel Injection molding and Drilled
  • Decent surface finish
  • Relatively simple shape
  • Drill holes
2 *Manufactured like this due to materials used and its specific shape 14ignitor.JPG
Inner Fan Fencing Guard Prevent Injury Painted Steel Bent/Rolled and Welded
  • Shape follows a radial path
  • Thin wire-like material
2 *Manufactured like this due to the shape achieved, s flat coil fence 14fencing.JPG
Circuit Board Controls heater function, Serves as user interface, Provides feedback Silicon, Plastic, Copper, Solder, Electric Components- Resistors, Capacitors, LEDs Printed and Machine Soldered
  • Common process for circuit boards
  • Consistent solder marks
5 (Given a 5 due to sheer amount of pieces involved and delicacy of the part) *Manufactured like such to allow for each piece to fit and allow for all components of part to work together.
  • Standard Computer Circuit Board
14circuitboard.JPG
Mounting Brackets (2) Mounts Bottom Heater Cylinder to Temperature/Pressure gauges Steel Pressed, Bent, Drilled
  • Thin steel
  • No mold marks
  • Drill holes
3 *Manufactured like such to obtain a specific shape to allow for the components purpose to be carried out 14bracket.JPG
Control Panel Covers (2) Protect Circuit Board and display Heater information Steel Pressed and Bent
  • No mold marks
  • Simple shape
  • Thin steel
2 *Manufactured like such to maximize ease of production and due to its simple shape 14controlcover.JPG
Ignitor Power Source Provides power to the ignitor Plastic, Copper, Rubber Injection Molding, Extruding for Wire
  • Specific plastic shape
  • Riser present
  • Common manufacture process for wire
3 *Manufactured like such to achieve specific shape and purpose 14pump.JPG
Motor Turn fan to blow heat from heater Steel, Plastic, Rubber, Copper, Aluminum Cast, Cut, Drilled, Pressed (fan Blades), Turned
  • Boring in center of pieces
  • Rough texture on some pieces
  • Decent finish on some parts
  • No mold lines and Thin steel (Fan)
5 *Manufacture like such to achieve specific shape and purose
  • NOTE: Due to poor condition of motor from rust, and potential to break components, the motor was left in 1 piece)
14motor.JPG
Bottom Heater Cover Serve as a mounting point and shield for inner components Steel Pressed, Punched
  • Thin steel
  • Easy shape
  • Distinct Punch holes
2 *Manufactured like such due to shape and ease of production
  • Painted for cosmetics
14bottomcover.JPG
Top Heater Cover Shields inner components and serves as barrier to people Steel Pressed, Punched
  • Thin steel
  • Easy shape
  • Distinct Punch holes
2 *Manufactured like such due to shape and ease of production
  • Painted for cosmetics
14heatercover.JPG
Fuel Tank Hold fuel Steel Pressed, Punched, and Welded
  • Simple shape
  • Made in 2 parts
  • Specific holes for other components
2 *Manufactured like such due to shape and ease of production
  • Tank is 13 gallons
14tank.JPG
Heater mounting frame Serve as a spot for user to hold Steel, Plastic Bent, injection molding (plastic handle)
  • Steel tube stock
  • Bend marks- Corners become flatter
  • Decent plastic finish (Handle)
2 *Manufactured like such due to shape and specific purpose 14handle.JPG
Wheels (2) Make heater mobile Steel, Rubber Injected, Cast (Steel rim)
  • Riser on tire
  • Mold lines
2 *Manufactured like such due to shape, materials, and specific purpose 14wheel.JPG
1/2" Phillips Head Screws (Approx. 60) Fasten other components Steel Cold Forging
  • No mold lines
  • Thin diameter
2 *Manufactured like this due to thin diameter, and ability to use wire as raw material with malleability of steel 14screws.JPG


Component Summary

Note: Specific pieces of information such as manufacturing process, evidence of the process, as well as why a specific process was used is located in the chart above.


Although most of the heater was made of steel, different materials were used depending one the purpose of the component. For example, copper, silicon, and plastics were used in the circuit board to achieve the job of being the controlling component in the heater. If just steel were used, the circuit board would not work (since it would not produce a functioning computer chip). This is also the case with the wheels, since if one had steel wheels rather than rubber, not only would traction be lost, but it would be much heavier.


Material choice and shape both affect the manufacturing processes of each part. Certain processes will work only in specific cases, such as turning with axial symmetric shaped components. Also, die casting may only work with specific metals/materials, and specific size components. This is the case with the heater as well. As listed above, there are many different types of manufacturing processes depending on the shape and material. The various inner heating cylinders were made by rolling steel, due to the fact that their shape enabled this processes to be the most efficient for production. Also, the various plastics were injection molded, as plastic as a material makes this processes very easy. Depending on the shape and material, each part used a specific processes to obtain its finished form.


Almost every single component on the heater has a specific shape that aids in its function. The whole heater itself is in a cylinder shape, which allows for the more efficient transfer of heat. However, there are 2 components inside the heater in which the shapes are very unique to the heater. Both the ignitor and inner heat exhaust cylinder plate have 2 specific shapes that are shown above in the chart. The ingitor has as shape that resembles a fan blade, however, it is stationary. This allows for the air that comes from the fan to be directed toward the inner heat exhaust cylinder plate. When it does this, due tot eh exhaust cylinder plate's shape, the air get directed once again, this time into the inner heat exhaust cylinder, to supply the flame inside with air. Each of these parts has a specific shape that allows for the increased functionality of the heater.


As far as the use of each component in functionality or cosmetics, every piece in the heater has a functional purpose. The 2 inner heat cylinders exchange heat, the electric motor blows it, the fencing guard provides a barrier preventing foreign materials from getting into the system, and the fuel tank holds the fuel for the system. The outer heater cylinders, however, not only are functional in that they provide a cooler, safer surface for those around the heater, and protection for the inner components, but also serves to make the heater look presentable by covering the raw parts inside, and having a painted surface. This make the outer heater cylinders functional and cosmetic, fitting very nicely with the function of every other component in the heater.

Design Revisions

While recognizing the possible constraints that the original design team may have faced, we still believe that there are other design configurations which we think would be better suited to this heater than the ones implemented by the designers. The design revisions we have made seek to improve not only the overall performance and lifespan of the heater, but also to increase its portability as well as its safety. Below is a breakdown of the 3 main areas of concern that we felt needed to be redesigned.

Revision 1

Component/System: Fuel feed lines and Return connectors.

Main Concern:

As it stands, the lines can only be connected by forcing its opening into the fuel injector outlet and supporting it in place using a small barb attached to the injector. The main problem with the system is that in case the heater is subjected to any rigorous motion, the lines could easily become disconnected, posing huge safety concerns for anyone in the heater’s vicinity.

Redesign Solution:

To avoid this hazard, we propose a change of the entire connection system. Instead of relying on force fitted, barb supported connectors; we would fit sliding sleeve connectors, comparable to those at the end of air compressor hoses. These would firmly and securely attach the feed lines to the fuel injector, improving the safety of the heater. Moreover, as opposed to the original connector, these do not reply on being forced in order to connect or disconnect them from the injector inlet, hence making them less susceptible to wear and tear, helping them last longer.


Revision 2

Component/System: Electric Motor

Main Concern:

Currently, the electric motor is showing significant signs of rust. Overtime, we believe that this would reduce the overall efficiency and performance of the motor, possibly from increased friction between corroded parts. This would have a negative effect on the heaters ability to heat spaces. Moreover, there is a high possibility that the motor, as a result of the above mentioned, would become nosier, an undesirable trait.

Redesign Solution:

1) To eliminate the chance of having rust deteriorate the performance of the motor, and in turn, that of the heater, we propose replacing the motor’s iron casing with one cast from stainless steel. This would inevitable increase cost, but would all but guarantee a longer lifespan for the motor.

2) To eliminate the chance of having rust deteriorate the performance of the motor, and in turn, that of the heater, we propose replacing the entire motor unit with a ball bearing motor system. These are not only well protected from rust, but are quieter, easier to take apart for maintenance, lighter and relatively inexpensive. Not only would this eliminate our rust concerns, but in would also reduce the weight of the heater, making it a lot more portable, while making it operate in a quieter, more desirable fashion.

3) To eliminate the chance of having rust deteriorate the performance of the motor, and in turn, that of the heater, we propose coating the motor’s iron casing with a enamel paint which would provide more than adequate protection from the elements, and would ensure a longer lifespan for the heater.


Revision 3

Component/System: Fuel Tank

Main Concern:

When filled to capacity, the current fuel tank can hold up to 13 gallons of fuel, adding approximately 88 pounds to the overall weight of the heater, bringing its overall weight to well over 100 pounds. Moving this around would be a tall order for a single person to accomplish, even with the aid of the attached wheels. Equally as alarming is the fact that due to its weight, one would require the assistance of a reasonably large vehicle to transfer the heater to and from a refilling station, a huge inconvenience for people without the man power and appropriate vehicle.

Redesign Solution:

To solve this problem, we propose halving the size of the fuel tank, from 13 to 6.5 gallons. This would significantly improve the portability of the heater, making it lighter as well as easier to move. This redesign; however, comes at a cost. The reduction in tank size reduces the run time of the heater. In spite of this, we still recommend this change because it still guarantees at least 4 hours of continuous heating, at high power. When put into consideration that the heater comes with a thermostat which turns of the heater once the desired temperate is reached, the actual run time would certainly exceed 4 hours.


Solid Modeling

Components

In order to better illustrate our kerosene, we chose to solid model it at the component level. Since the heater was not too complex, most of the heater was modeled. The modeled components include the gas tank, the front and rear handles, the wheel, the bottom stand, the circuit board panel, and the outer cylinder. These components were chosen because it shows how the exterior of the heater is assembled.

Program

The program used for the solid modeling was SolidWorks 2009. This program was used because it was available through the mini Baja club at UB. SolidWorks 2009 was also chosen because it has many great features including several assembly commands and new motion studies.


Models

Assembly Exploded View
14finalassembly.jpg
14explodedfinalassembly.jpg

Engineering Analysis

Key Component(s): Heater Cylinders

In designing and manufacturing this heater, an engineer would need to take many things into consideration, specifically the material and the heater's effect on it.

Before the heater is designed, the company would have an idea of what they wanted to achieve by the heater. They would have a target temperature and BTU output for the engineer to use to aid in designing the heater. Using these key pieces of information, an engineer would be able to choose what what material would be most functional and cost effective in producing the heater.


Knowing the BTU output per gallon of kerosene, at 135000, and that the heater will burn approximately 1.6 gal/hr, the BTU output per hour of the heater can be calculated by multiplying 135000BTU/gal by 1.6gal/hr. This yields a value of 216000BTU/hr. This would be the value if the heater was 100% efficient, which most likely is not the case.

As labeled on the heater, the maximum operating temperature is 1165 degrees Fahrenheit and it produces 210000BTU/hr.


By knowing the heater temperature output, an engineer can make relatively sound decisions on what materials to utilize for the inner cylinders. Since the inner cylinders would become extremely hot, the material used must be able to withstand melting and deforming during the continual use of the heater. The material must also be cost effective in order for the product to maximize profit.


Assuming 1165 degrees to be the operating temperature, it can be compared to properties of possible materials to be used.

  • Aluminum- Melting Point: 1221 degrees F (From Here)
  • Steel- Melting point: 2500 degrees F (From Here)
  • Iron- 2750 degrees F (From Here)
  • Copper- Melting Point: 1981 degrees F (From Here)


Based off of these values, an engineer can instantly make the conclusion not to use aluminum for the inner casing due to its melting point being extremely close to the max operating temperature. However, these values are not the only thing to influence the decision. Cost of materials and other metallic properties are also a factor. Based off of cost, the engineer would eliminate copper, as it is very expensive and would be very costly to use. This would leave steel and iron as the last choices of the above. Iron, however, can be eliminated if the shape of the heater is kept in mind. The cylinders are thin and round. It would be more time consuming to shape iron in that manner rather than steel, as steel tends to be easier to shape, let alone not as brittle.

Using the process of eliminations, Steel would be the most purposeful of the above materials, and would be the one most likely chosen by an engineer in producing the inner heater cylinders.

Gate 4 - Critical Design Review

Similar to the procedure of taking the heater apart, restoring it to the original state also seemed relatively easy. We did; however, run into a few minor problems, which we resolved, that caused the process to be slowed slightly. (For more information on the problems, see section under the following chart.)


Product assembly

The scale of ease of this chart is on a range from 1 to 5, with 5 being the most difficult. A rating of 1 can be comparable to a task that can be completed on your first try, where as a rating of 5 may require multiple attempts to complete.

Step # Process Difficulty Tool Needed Visual
1 Attached Heater Mounting Frame to Fuel Tank 1 #3 Phillips Screwdriver 14handle.JPG
2 Replace Ignitor Power Source to Fuel Tank 1 By hand 14pump.JPG
3 Attach Bottom Heater Cover to Fuel tank 1 #3 Phillips Screwdriver
  • (4 Screws)
14bottomcover.JPG
4 Draw Wires and Tubes Back through Bottom Cover 3 By hand 14hoses.JPG
5 Replace Inner Heat Exhaust Cylinder Plate 1 #3 Phillips Screwdriver
  • (2 Screws)
14heatplate.JPG
6 Replace Ignitor on Fuel Injector 1 #3 Phillips Screwdriver
  • (1 Screw)
14ignitor.JPG
7 Replace Fuel Injector on Inner Heater Exhaust Cylinder 1 #3 Phillips Screwdriver
  • (4 Screws)
14injector.JPG
8 Replace Pressure Gauge Bracket to Exhaust Cylinder Plate (Bottom in Picture) 1 #3 Phillips Screwdriver
  • (2 Screws)
14bracket.JPG
9 Replace Temperature Gauge Bracket to Bottom Heater Cover (Top in Picture) 1 #3 Phillips Screwdriver
  • (2 Screws)
14bracket.JPG
10 Replace/Attach Inner Heater Exhaust Cylinder Inside Inner Heater Cylinder 2 #3 Phillips Screwdriver
  • (8 Screws)
14exhaust.JPG
11 Replace/Attach Inner Heater Cylinder to Bottom Heater Cover 1 #3 Phillips Screwdriver
  • (4 Screws)
14innertube.JPG
12 Replace Hoses and wires to Fuel Injector 3 By hand 14hosesinjector.JPG
13 Replace Circuit Board 1 #3 Phillips Screwdriver
  • (2 Screws)
14circuitboard.JPG
14 Attach Wires to Circuit Board 4 By hand 14circuitwires.JPG
15 Attach Ground Wires (3 Wires with 2 Ground Locations) to Bottom Heater Cover 1 #3 Phillips Screwdriver
  • (2 Screws)
14Ground.jpg
16 Connect Motor Power Source Wires 2 By hand 14motorpower.JPG
17 Replace Electric Motor and Fan to Bottom Heater Cover 1 #3 Phillips Screwdriver
  • (4 Screws)
14motorwire.JPG
18 Replace Rubber tube from Motor to Injector 1 By Hand 14Fueltube.JPG
19 Replace Control Panel Covers (2) 1 #3 Phillips Screwdriver
  • (4 screws each)
14controlcover.JPG
20 Replace Top Heater Cover to Bottom Heater Cover 1 #3 Phillips screwdriver
  • (6 Screws)
14heatercover.JPG
21 Replace Inner Fan Fencing Guard on Back of Heater 1 By Hand 14fencing.JPG


Overview of Product Assembly

Problems Faced

We faced only one major problem when restoring the heater. This was when we replaced the fuel injector. By mistake, we fastened it upside-down, which caused use to not be able to replace the fuel lines as they were to short when it was flipped. To fix this, we unscrewed the injector, and replaced it in the correct position. This allowed the lines to have the correct length, and allowed for us to hook up the necessary lines.


Differences from Dissection

Overall, putting the heater back together was extremely similar to the dissection. The same tools were used, as the same parts were replaced with ease. The only major difference we faced was the fact that we had to decide where all the wires and tubes went, rather than taking it apart where we just pulled them out regardless. Despite the difference, we still managed to restore the heater and put it back together in its entirety.


Product Overview

Once we completed the re-assembly of the heater, we took it upon ourselves to test the product to be sure we put it back together correctly. Once the pieces were replaced, we plugged the product in. As instructed, we did not use any kerosene and did not actually have a flame, however, the motor/fan as well as the ignitor still worked. We did notice that regardless of when the switch was in the on or off position, the heater stayed on. In order to fix this, we reversed the wires to see if we may have mistaken the positions. After retesting the product, we found it to have the same result as before. Based on this, we came to the conclusion that the switch most likely never worked to begin with, as if we had the wires incorrectly placed, the heater would not work to begin with. In order to fix this, a new switch should result in the heater working properly.


Additional Suggestions

Outside of what suggestions and design revisions already stated in the previous gate, we believe the heater to be well put together for its purpose. It does not have overly complex parts with complex functions for its intended purpose. This results in a product that is fairly reliable, and if need be, easy to fix. Because of this, we feel that no more revisions are needed to the product.

Conclusion

References

Note: the following links are cited in the above material through linked texted where the material is used. Example- The temperatures in the Engineering Analysis section have the link in the "(From here)" button after each temperature.


http://images.google.com/imgres?imgurl=

http://www.chemicalelements.com/elements/al.html

http://education.jlab.org/qa/meltingpoint_01.html

http://www.chemicalelements.com/elements/cu.html