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| − | == Work Proposal== | + | == 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. |
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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.
| + | == Introduction == |
| − | 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:
| + | '''Group Members''' |
| − | {|border="1" cellpadding="5"
| + | *Salman Iqbal – Project Manager |
| − | |-
| + | *Jonathan Burkhart – Technical Expert |
| − | !Tool Name
| + | *Andrew Carroll – Wiki Manager |
| − | !Use
| + | *David Holewka – Communication Liaison |
| − | |-
| + | *Rusty Donlon – Technical and Communication Support |
| − | |Metric Ratchet Set
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| − | |Removing bolts from the casing/internal components
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| + | == Product == |
| − | |Metric Screw Driver Set
| + | *599 CC Honda Engine. |
| − | |Removing screws from the casing/internal components
| + | *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. |
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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]] |
| − | |Metric Torx Screw
| + | This page shows Group 19's Work Proposal, Management Proposal, and Initial Product Assessment |
| − | Driver Set
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| − | |Removing Torx head screws from the casing/internal components
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| + | [[Group 19: Gate 2]] |
| − | |Pliers
| + | This shows our Product Dissection Plan and our Causes For Corrective Action |
| − | |Removing hoses and clamps
| + | |
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| − | |-
| + | [[Group 19: Gate 3]] |
| − | |Needle Nose Pliers
| + | This shows our Product Documentation, Component Summary, Design Revisions, Solid Modeling, and Engineering Analysis |
| − | |Removing small clamps
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| + | [[Group 19: Gate 4]] |
| − | |Vice Grips
| + | This is our Product Reassembly and Recommendations |
| − | |Holding loose components to the engine
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| + | == References == |
| − | |Hammer/Mallet
| + | Wahlster, K. (2009). 1994 Honda CBR600F2. Retrieved from Bke Bandit: http://www.bikebandit.com/houseofmotorcycles/honda-motorcycle-cbr600f2-1994/o/m2043 |
| − | |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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| − | |}
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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 == | + | |
| − | Our group will be constructing a Gantt chart with specific instructions and timelines for when to complete each component of the project. The Gantt chart will consist of the deadlines and tasks that will need to be completed throughout the course of the project. We will maximize our group time in the lad, disassembling and analyzing each component’s function. We will be taking detailed written and visual records and posting them on our wiki site regularly to keep group members updated on our progress. We plan on meeting in front of Student Union before our scheduled lab times, 2 to 3 times a week. Our meeting times will be Tuesdays 4:15pm – 6:30pm and Wednesdays 5:00pm-8:00pm for the next several weeks.
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| − | [[Image:Gantt-19.jpg]]
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| − | The progress of our group depends on dedication and alertness to our work schedule as displayed in our Gantt chart. Each member has responsibilities that must be accounted for in order to keep the project moving forward and complete each component on time. Our Communication liaison will ensure that all group members are updated regularly on meeting times and everyone is always caught up on the task at hand at any given day.
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| − | The roles of each of our group members are defined as follows:
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| − | '''Project Manager:''' Salman Iqbal
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| − | The project manager’s job is to oversee all processes of the project, from the initial product assessment to the final delivery. He is responsible for making sure that all the work done during the lab hours is safe, substantial and detailed. He is to assess each group member’s work, making sure that each member is working diligently and is able to get the required amount of work done as prescribed by the Gantt chart. The project manager is also responsible of ensuring the quality of work done by every member and optimizing meeting times to match the schedule of the Gantt chart.
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| − | '''Technical Expert:''' Jonathan Burkhart
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| − | The technical expert is responsible for familiarizing himself with various technical aspects of the project. Such aspects include 3-D Modeling (Rhinoceros NURBS modeling for Windows and AutoCAD 2009), expert knowledge of the required tools and dissection procedures and ensuring that the dissection process is on pace with the Gantt chart and is done with the proper safety precautions.
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| − | '''Communication Liaison:''' David Holewka
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| − | The primary responsibility of the communication liaison is to maintain contact between the professor and the teaching assistants. Also, in the case that a member of group is unable to attend a meeting, the communication liaison is to bring that member up to date on any progress that has been made so far. He is also in charge of sending meeting reminder e-mails after each meeting and preparing the times and reviewing the Gantt chart for the subsequent meeting.
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| − | '''Wikipedia Manager:''' Andrew Carroll
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| − | The Wikipedia Manager maintains and updates the group’s Wikipedia page with photos, video and up to date developments on the project. He is also accountable for making sure that all necessary information such as the entire detailed dissection is posted on the wiki along with corresponding pictures. This will be followed by clear and comprehensive reports of the Preliminary Project Review, Coordination Review, Critical Project Review and Final Delivery. The Wikipedia manager will be expected to complete these assignments before each respective delivery date.
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| − | '''Technical and Communication Support:''' Rusty Donlon
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| − | The Technical and Communication Support will be accountable for assisting all group members with their respective tasks. His main objective is to take visual records (i.e. pictures, videos) of each step of the product dissection and assembly and assist the Wikipedia Manager in updating the wiki page. He will also assist the Technical Expert in creating 3-D models of certain parts that require more attention and making these parts available to the entire group.
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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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| − | == Product Dissection Plan ==
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| − | The Honda engine is a product that is not intended to be taken apart easily. Many of the parts are put together by machines that exert a massive amount of force on those parts. This way, the engine is able to sustain high temperatures as well as very high pressures. However, for our disassembly plan, we had to use a variety of smaller tools ranging from Philips head screwdrivers to socket wrenches. These tools and their functions are labeled in the following table.
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| − | We established a difficulty scale to measure the ease of each step. The scale utilizes two components in the form of “A/B.” “A” denotes simplicity ranging from one to five. One being a very easy step to perform and five requiring multiple attempts and tools. “B” denotes how obvious the steps were, ranging from one to two. One being easy to see the step and two being thought intensive. For example, a difficulty of “4/2” represents a step that is complicated and requires thought.
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| − | The steps taken in the dissection process as well the tools required for each step are outlined in Table 1 and Table 2. Any obstacles that we faced are also documented on the following pages.
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| − | '''Figure 1:'''
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| − | {|border="1" cellpadding="5"
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| + | |
| − | !STEPS
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| − | !TOOLS
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| − | !DIFFICULTY
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| − | (A/B)
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| − | |Removed filter cover
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| − | |Philips head screwdriver
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| − | |1/1
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| − | |Removing casing beneath filter
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| − | |Philips head screwdriver
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| − | |1/1
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| − | |Removed air intake, revealed springs with black caps and valves
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| − | |Philips head screwdriver
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| − | |2/1
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| − | |-
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| − | |Removed upper casing
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| − | |10mm socket wrench
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| − | |2/1
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| − | |-
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| − | |Removed carburetor
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| − | |N/A
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| − | |3/1
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| − | |-
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| − | |Removed alternator
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| − | |8mm socket wrench
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| − | |2/2
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| − | |Removed outside casing over chain from crankshaft to camshafts
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| − | |8mm socket wrench
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| − | 10mm socket wrench
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| − | |3/2
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| − | |-
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| − | |Removed more components of crankshaft chain
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| − | |14mm socket wrench
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| − | |1/1
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| − | |Removed the outside casing of the transmission
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| − | |10mm socket wrench
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| − | 14mm socket wrench
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| − | |3/2
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| − | |Recorded an experimental video – shows the rotation of the crank shaft results in rotation of the air flow and exhaust flow regulator
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| − | |Camera
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| − | |1/1
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| − | |Removed a piston that was adding tension to the spring on the side of the engine
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| − | |10mm socket wrench
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| − | |3/1
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| − | |Removal of shafts regulating air flow through removal of the piston
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| − | |8mm socket wrench
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| − | |2/1
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| − | |Loosened and removed nuts & bolts from main body
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| − | |10mm socket wrench
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| − | |1/1
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| − | |Removed torx screw from front of engine to disassemble the upper half
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| − | |Torx screwdriver
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| − | |2/1
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| − | |Removal of water pump
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| − | |10mm socket wrench
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| − | |3/1
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| − | |Further removal of bolts
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| − | |10mm socket wrench
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| − | |1/1
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| − | |Removal of radiator hoses
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| − | |Removal by hand
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| − | |1/1
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| − | |}
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| − | '''OBSTACLE:''' The group needed larger allen keys to remove the valves from the pistons. We went to the machine shop to obtain the proper tools but the machine shop was closed. We decided that it would be easier to flip the engine over and work from the bottom. This way, we were able to get to the transmission easily.
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| − | '''Figure 2:'''
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| − | {|border="1" cellpadding="5"
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| − | !STEPS
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| − | !TOOLS
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| − | !DIFFICULTY
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| − | A/B
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| − | |Removed bottom plate, exposing the pistons, the transmission and the crankshaft
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| − | |10mm socket wrench
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| − | |4/2
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| − | |-
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| − | |Recorded an experimental video of how we think the engine works
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| − | |Camera
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| − | |1/1
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| − | |-
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| − | |Removed interior bolts, making way towards the transmission
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| − | |13mm socket wrench
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| − | |3/2
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| − | |-
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| − | |Removed radiator fluid filter
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| − | |10mm socket wrench
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| − | |2/2
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| − | |-
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| − | |Removed transmission: revealed a system of gears that dictates the motion of the pistons which control the motion of the motorcycle
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| − | |14mm socket wrench
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| − | |4/2
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| − | |-
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| − | |Further removed the main gears revealing an intricate system of springs that would be difficult to remove and reassemble. This would also require some powerful tools that we do not have access to.
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| − | |N/A
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| − | |1/1
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| − | |}
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| − | '''OBSTACLE:''' The group debated on how the transmission system works. We looked at all the dissected parts and talked about how the movement of the gears affects each part resulting in the movement of the motorcycle. We recorded a video on how we think this process takes place.
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| − | == Causes For Corrective Action ==
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| − | As we progressed through our Work and Management plans, we encountered several problems. These problems led to obstacles in our dissection procedure that needed to be addressed. While our original plan was to start at the top of the engine and take it apart piece by piece, we found that an easier way to access the transmission was by inverting the engine. Getting a better understanding of how the transmission worked took longer than expected, due to the fact that we have very little knowledge of motorcycle engines. To account for this, we extended our meeting times so that we could spend more time in the lab and improve our understanding of the transmission. We finally determined how the transmission functions through a series of different trials. Each trial consisted of us turning a different part of the transmission until the gear pieces would shift or slide in one direction or another. From the knowledge we have of transmissions, we were able to decide what gears were neutral, first, second, etcetera.
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| − | We also noted an inaccuracy in our Gantt chart. Our time slot for the “Causes for Corrective Action” step was placed too early for us to complete. It should have been placed in a time slot after the “Disassembly” process was to be finished.
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| − | Although there were some problems and obstacles in our Work and Management plans, things went as smoothly as possible. Our Gantt chart provided an accurate time line that helped keep us on top of what needed to be done. Being able to meet as a group two to three times a week allowed our group leader to keep us organized and on track. As stated in our Management Proposal, we had allotted seven and a half hours for the dissection and understanding of the engine, “The dissection is expected to take approximately ten hours. Five hours would be used to disassemble the product. Two and half hours would be dedicated to understanding the internal components and their functions” (Management Proposal). However, the actual Disassembly process took us three hours to complete, leaving us with ample time to focus on the engine transmission. Up to this point, we are on schedule to complete the project on time.
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| − | For problems we will face in the future, we will need to find quick ways to resolve them without putting a delay on the other processes outlined in our Gantt chart. One problem that we may face is that the reassembly process may take longer than we expect. This is due to the fact that there are many different size screws and parts to the engine. To resolve this issue, we will extend our meetings to accommodate enough time to reassemble the engine. The notes and pictures that we have taken during the disassembly procedure will help guide us to correctly pull together the engine. Also, with scheduling conflicts and exams, some group members will not be able to attend all the meetings. The group members that are available will meet and keep the other members updated through e-mails. Since there is limited space in the lab and an excess of groups working at once, some small parts such as screws, nuts and bolts may have been misplaced during the dissection process. The Technical Expert of our group, Jonathan Burkhart will be responsible for documenting any missing parts. Our Communication Liaison, David Holewka will contact Phil Cormier or Erich Devendorf and inform them of any missing parts.
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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.
