Group 19 - Honda Engine

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== Work Proposal==
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== Executive Summary ==
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The purpose of this project was to reinforce key skills that we have learned throughout our engineering careers here at the University at Buffalo. The project helped us showcase our technical writing skills, improve group work skills and help us make decisions engineers make every day. We were part of a project design team and our objective was to take a product, disassemble it, and investigate various aspects of its design and manufacturing techniques used to engineer the product. A Request for Proposal, Preliminary Project Review, Coordination Review, Critical Project Review and Delivery were the five deliverables for the project. We had to prepare a work and management proposal which outlined our plan for the project. Next, we had to dissect our product and submit a Causes for Corrective Action plan which highlighted any difficulties we encountered during the dissection. Next, we were asked to submit a Component Summary and construct solid models of our product. We conducted a Critical Project Review consisting of a Product Reassembly Plan and reassembled our product. The final step of the project was the Deliver where we completed minor revisions on all of our technical documents and submitted a final version of our report.
  
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Our group, Group 19, has been tasked with disassembling a Honda engine.  Our engine is an inline four cylinder.  This means that it contains four cylinders and pistons adjacent to one another.  We plan to start disassembly at the top in the air filter and work downward.  This seems like the easiest approach, as the air filter will yield way to the cylinders of the engine.  Figure 1 shows the top view of the engine.  We then plan to disassemble the cylinders and make way through to the crank shaft. 
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== Introduction ==
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There are a widespread number of tools that may be necessary to help disassemble the engine.  The outermost parts of the engine are simple enough to disassemble.  Standard screw drivers and a ratchet can mostly be used to remove casings, and pliers can be used to remove most hoses without a problem.  For the internal parts, vice grips and WD-40 may be used to remove some jammed components that are better set into place.  Figure 2 shows a more detailed breakdown of the tools and possible uses.
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Figure 2:
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'''Group Members'''
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{|border="1" cellpadding="5"
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*Salman Iqbal – Project Manager
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*Jonathan Burkhart – Technical Expert
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!Tool Name
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*Andrew Carroll – Wiki Manager
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!Use
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*David Holewka – Communication Liaison
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*Rusty Donlon – Technical and Communication Support
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|Metric Ratchet Set
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|Removing bolts from the casing/internal components
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== Product ==
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|Metric Screw Driver Set
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*599 CC Honda Engine.
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|Removing screws from the casing/internal components
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*The engine was not functional when we received it, therefore, we could not test it.
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*We focused on analyzing the transmission instead of the entire engine.
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*The transmission functioned very well and we were able to observe and understand gear-shifting after dissecting our product.
  
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|Metric Allen Keys
 
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|Removing Allen head screws from the casing/internal components
 
  
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[[Group 19: Gate 1]]
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|Metric Torx Screw
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This page shows Group 19's Work Proposal, Management Proposal, and Initial Product Assessment
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Driver Set
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|Removing Torx head screws  from the casing/internal components
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[[Group 19: Gate 2]]
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|Pliers
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This shows our Product Dissection Plan and our Causes For Corrective Action
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|Removing hoses and clamps
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[[Group 19: Gate 3]]
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|Needle Nose Pliers
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This shows our Product Documentation, Component Summary, Design Revisions, Solid Modeling, and Engineering Analysis
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|Removing small clamps
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[[Group 19: Gate 4]]
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|Vice Grips
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This is our Product Reassembly and Recommendations
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|Holding loose components to the engine
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== References ==
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|Hammer/Mallet
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Wahlster, K. (2009). 1994 Honda CBR600F2. Retrieved from Bke Bandit: http://www.bikebandit.com/houseofmotorcycles/honda-motorcycle-cbr600f2-1994/o/m2043
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|Removing attached/rusted on components
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|WD-40
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|Loosening components that may be difficult to move after setting
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This dissection is expected to take approximately 10 hours.  Five hours would be used to disassemble the product. Two and a half hours would be dedicated to understanding the internal components and their functions.  The final two and a half hours would be spent reassembling the engine properly.
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There are several large challenges involved in the disassembly of the engine.  Firstly, there are many small parts and components that we are unfamiliar with.  This will make it difficult to understand how it works.  Additionally, we found that the engine itself has a highly intricate design.  This coincides with the first obstacle, meaning that the high degree of complication will make understanding the inner workings of the engine difficult.  The last impediment we found was that the engine is heavy.  Being unable to physically manipulate the entire product makes dissection difficult, as some components may be in hard to reach places.
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Our group has a small arrangement of capabilities among our members.  John Burkhart has some limited solid modeling experience that will need to be supplemented to complete the project.  All members are able to operate a computer, as well as most tools and equipment we will be using to disassemble the engine.  In addition, all members of our group have AutoCAD experience, and are able to use that as a possible presentation tool.
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Our group also has several disadvantages.  No members of our group have ever made a Wiki, meaning that someone will have to take time to learn how to develop and maintain one.  Also, none of our group members have any automotive experience.  This lack of knowledge will hinder our group in identifying the components of the engine.
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== Management Proposal ==
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== Initial Product Assessment ==
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After receiving our product, the entire group analyzed the various components and concluded that we had a HONDA motorcycle engine. Our general product dissection plan consists of taking apart the air intake and filter, moving down to the pistons and finishing at the crank shaft, all the while working towards the bottom of the engine. On each step, we will take detailed notes on all the components of our product and constantly update our wiki page while optimizing our work time in the lab.
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'''Intended Use:'''
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The intended use of our product is to produce power through a combustion process that takes place inside the engine block. It is part of a motorcycle that can be used both professionally and recreationally. The functions of our product include supplying power to the mechanical components of a motorcycle resulting is the turning of the wheels and creating motion. The engine’s alternator, when functional, provides energy to the battery which in turn provides electricity to power the electronic components of the motorcycle.
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'''How it Works:'''
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The engine process starts by taking in air and gas through the air intakes. Within the engine, there is a combustion reaction which converts the chemical energy of the gases into mechanical energy. This energy propels the pistons and turns the crankshaft which results in the rotation of the wheels and movement of the motorcycle. Meanwhile, frictional forces inside the engine act on various components creating thermal energy. The alternator provides electrical energy which in turn charges the battery enabling many electronic functions on the motorcycle.
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'''Complexity:'''
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This product is extremely complex consisting of many different sized components, each of which involves the use of smaller parts resulting in various functions. The engine is able to conduct many different processes simultaneously with each part moving at extremely rapid speeds. It is able to convert one form of energy into another continuously, providing this energy to the drive train and the alternator.
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'''Materials:'''
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The engine is composed of various metals such as steel, copper and aluminum creating the major components of the engine block.  There are also rubber and plastic tubes present as well as grease, glue, oil and solder.
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'''User Feedback:'''
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This engine provides sufficient power to propel a motorcycle and optimize mileage. It creates high amounts of vibrations and outputs a significant amount of heat and sound.  When installed, the system functions efficiently providing enough power to the drive train to propel a motorcycle. Despite its effortless operation, the engine is difficult to maintain without proper knowledge of all of its systems and parts.
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'''Alternatives:'''
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Some alternatives to this product are electric motors and hybrid motors. Electric motors are more expensive to purchase but are cheaper to operate. Hybrid motors are also more expensive than our current engine and are also cheaper to operate and maintain. However, our product is less expensive, outputs more power to the drive train and is much more universal for a mechanic to work on.
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Latest revision as of 14:39, 16 December 2009

Contents

Executive Summary

The purpose of this project was to reinforce key skills that we have learned throughout our engineering careers here at the University at Buffalo. The project helped us showcase our technical writing skills, improve group work skills and help us make decisions engineers make every day. We were part of a project design team and our objective was to take a product, disassemble it, and investigate various aspects of its design and manufacturing techniques used to engineer the product. A Request for Proposal, Preliminary Project Review, Coordination Review, Critical Project Review and Delivery were the five deliverables for the project. We had to prepare a work and management proposal which outlined our plan for the project. Next, we had to dissect our product and submit a Causes for Corrective Action plan which highlighted any difficulties we encountered during the dissection. Next, we were asked to submit a Component Summary and construct solid models of our product. We conducted a Critical Project Review consisting of a Product Reassembly Plan and reassembled our product. The final step of the project was the Deliver where we completed minor revisions on all of our technical documents and submitted a final version of our report.

Introduction

Group Members

  • Salman Iqbal – Project Manager
  • Jonathan Burkhart – Technical Expert
  • Andrew Carroll – Wiki Manager
  • David Holewka – Communication Liaison
  • Rusty Donlon – Technical and Communication Support

Product

  • 599 CC Honda Engine.
  • The engine was not functional when we received it, therefore, we could not test it.
  • We focused on analyzing the transmission instead of the entire engine.
  • The transmission functioned very well and we were able to observe and understand gear-shifting after dissecting our product.


Group 19: Gate 1 This page shows Group 19's Work Proposal, Management Proposal, and Initial Product Assessment

Group 19: Gate 2 This shows our Product Dissection Plan and our Causes For Corrective Action

Group 19: Gate 3 This shows our Product Documentation, Component Summary, Design Revisions, Solid Modeling, and Engineering Analysis

Group 19: Gate 4 This is our Product Reassembly and Recommendations

References

Wahlster, K. (2009). 1994 Honda CBR600F2. Retrieved from Bke Bandit: http://www.bikebandit.com/houseofmotorcycles/honda-motorcycle-cbr600f2-1994/o/m2043

Retrieved from "http://gicl.cs.drexel.edu/wiki-data/index.php?title=Group_19_-_Honda_Engine&oldid=42539"
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