Group 26 - Pressure Washer
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[[Engineering Analysis for Group 26|Engineering Analysis]]<br> | [[Engineering Analysis for Group 26|Engineering Analysis]]<br> | ||
| − | == Gate 4: Product Reassembly Plan == | + | == Gate 4: Critical Project Review == |
| + | ===Product Reassembly Plan=== | ||
| + | The process for reassembling the pressure washer is almost the same process as disassembling it in reverse. If one can disassemble it, one can reassemble without much hassle. | ||
| + | :{| class="wikitable" style="text-align:center; height:150px; width:800px" border="1" | ||
| + | |- | ||
| + | | '''Step #''' || '''Process''' || '''Tools Necessary''' || '''Difficulty''' || '''Image''' | ||
| + | |- | ||
| + | | 1 || Disconnect two bolts on the gas tank. || 10 mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 2 || Remove the remaining bolt connecting the gas tank. || 8mm socket wrench || 1 || [[Image:Group26_21.jpg|100px]] | ||
| + | |- | ||
| + | | 3 || Remove the hose by squeezing the pressure clamp. || None (pliers are optional) || 2 || [[Image:Group26_3.jpg|100px]] | ||
| + | |- | ||
| + | | 4 || Disconnect the electrical wiring that is connected to the spark plug, sensor in the engine, and the power switch. || None || 1 || | ||
| + | |- | ||
| + | | 5 || Remove the fly wheel shield by disconnecting the four bolts holding it onto the engine. || 8mm socket wrench || 1 || [[Image:Group26_20.jpg|100px]] | ||
| + | |- | ||
| + | | 6 || Disconnect the springs that are attached to the carburetor. || None || 1 || | ||
| + | |- | ||
| + | | 7 || Remove the two nuts holding the exhaust to the engine. || 13mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 8 || Slide the exhaust and the gasket off the studded bolts. || None || 1 || [[Image:Group26_11.jpg|100px]] | ||
| + | |- | ||
| + | | 9 || Remove the two screws holding the air cleaner, the carburetor, and the gaskets to the intake manifold. || 10mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 10 || Slide the air cleaner, the carburetor, and the gaskets off of the studded bolts. || None || 1 || [[Image:Group26_9.jpg|100px]] | ||
| + | |- | ||
| + | | 11 || Remove the two bolts holding the heat shield to the side of the engine. || 8mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 12 || Remove the four bolts holding the valve cover to the top of the engine. || 8mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 13 || Take off the valve cover and the gasket. || None || 1 || | ||
| + | |- | ||
| + | | 14 || Remove the four bolts holding the head to the engine (There are two bolts located inside the head and two bolts located outside of the head). || 12mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 15 || Remove the head from the engine. || None || 1 || | ||
| + | |- | ||
| + | | 16 || Remove the rocker arm. || 10mm socket wrench || 1 || | ||
| + | |- | ||
| + | | 17 || One end of the rocker arm is connected to the rod and the other end is resting on the valve spring. || None || 1 || [[Image:Group26_29.jpg|100px]] | ||
| + | |- | ||
| + | | 18 || Remove the valve springs by pushing down on them and turning them to detach them from the valve. || None || 2 || | ||
| + | |- | ||
| + | | 19 || Remove the valves and the rods from the head. || None || 3 || | ||
| + | |- | ||
| + | | 20 || Remove the six bolts holding the engine cover in place. || 10mm socket wrench || 2 || [[Image:Group26_31.jpg|100px]] | ||
| + | |- | ||
| + | | 21 || Take off the engine cover and its gasket. || None || 1 || | ||
| + | |- | ||
| + | | 22 || If oil is located inside of the engine, drain it out into a pan and dispose of it properly. || Oil Dispenser and Funnel || 1 || [[Image:Group26_32.jpg|100px]] | ||
| + | |- | ||
| + | | 23 || Remove the cam shaft. It should easily slide out of the engine. || None || 1 || | ||
| + | |- | ||
| + | | 24 || Directly above the camshaft are two lifters that the rods were connected to. Remove those lifters from the engine. || None || 2 || | ||
| + | |- | ||
| + | | 25 || Attached to the crankshaft is the piston. There are two bolts holding the piston to the crank. Remove these bolts and slide the piston out of the top of the engine. || 10mm socket wrench || 2 || | ||
| + | |- | ||
| + | | 26 || Remove the nut holding the flywheel to the crankshaft. This nut is on the outside of the engine. || 22mm socket wrench || 1 || [[Image:Group26_26.jpg|100px]] | ||
| + | |- | ||
| + | | 27 || Remove the plastic cover and the metal guard from the flywheel. || None || 1 || | ||
| + | |- | ||
| + | | 28 || If necessary, after the nut, plastic cover, and the guard are removed, take a rubber mallet and hit the fly wheel to loosen it up. || Rubber mallet || 2 || | ||
| + | |- | ||
| + | | 29 || Once it is loose, remove the flywheel and then crank shaft. || None || 1 || | ||
| + | |- | ||
| + | | 30 || Engine is now disassembled || N/A || N/A || | ||
| + | |} | ||
'''Does your product run the same as before you dis-assembled it ''' | '''Does your product run the same as before you dis-assembled it ''' | ||
Revision as of 16:10, 7 December 2009
Contents |
Introduction
A requirement for MAE277, taught by Erich Devendorf, the Reverse Engineering Project is designed to help students familiarize themselves with the assembly of a product. Over the course of the semester, the students will work on five gates which will showcase the ongoing analysis of their products. This project will reinforce key skills that engineers utilize everyday.
Groups 25 and 26 were assigned a pressure washer. Rather than share entire product between two groups, the product was divided into two, with group 25 analyzing the compressor and with group 26 analyzing the engine.
Gate 1: Request for Proposal
This portion of the Reverse Engineering Project is designed to help the group become familiarized with the product, a pressure washer. A general work outline for the semester will be developed and will contain the following items: a work proposal, a management proposal, and an initial product assessment.
Work Proposal
Management Proposal
Initial Product Assessment
Gate 2: Preliminary Project Review
Causes for Corrective Action
Product Dissection Plan
Gate 3: Coordination Review
Component Summary
Design Revisions
Solid Modeled Assembly
Engineering Analysis
Gate 4: Critical Project Review
Product Reassembly Plan
The process for reassembling the pressure washer is almost the same process as disassembling it in reverse. If one can disassemble it, one can reassemble without much hassle.
Step # Process Tools Necessary Difficulty Image 1 Disconnect two bolts on the gas tank. 10 mm socket wrench 1 2 Remove the remaining bolt connecting the gas tank. 8mm socket wrench 1 
3 Remove the hose by squeezing the pressure clamp. None (pliers are optional) 2 
4 Disconnect the electrical wiring that is connected to the spark plug, sensor in the engine, and the power switch. None 1 5 Remove the fly wheel shield by disconnecting the four bolts holding it onto the engine. 8mm socket wrench 1 
6 Disconnect the springs that are attached to the carburetor. None 1 7 Remove the two nuts holding the exhaust to the engine. 13mm socket wrench 1 8 Slide the exhaust and the gasket off the studded bolts. None 1 
9 Remove the two screws holding the air cleaner, the carburetor, and the gaskets to the intake manifold. 10mm socket wrench 1 10 Slide the air cleaner, the carburetor, and the gaskets off of the studded bolts. None 1 
11 Remove the two bolts holding the heat shield to the side of the engine. 8mm socket wrench 1 12 Remove the four bolts holding the valve cover to the top of the engine. 8mm socket wrench 1 13 Take off the valve cover and the gasket. None 1 14 Remove the four bolts holding the head to the engine (There are two bolts located inside the head and two bolts located outside of the head). 12mm socket wrench 1 15 Remove the head from the engine. None 1 16 Remove the rocker arm. 10mm socket wrench 1 17 One end of the rocker arm is connected to the rod and the other end is resting on the valve spring. None 1 
18 Remove the valve springs by pushing down on them and turning them to detach them from the valve. None 2 19 Remove the valves and the rods from the head. None 3 20 Remove the six bolts holding the engine cover in place. 10mm socket wrench 2 
21 Take off the engine cover and its gasket. None 1 22 If oil is located inside of the engine, drain it out into a pan and dispose of it properly. Oil Dispenser and Funnel 1 
23 Remove the cam shaft. It should easily slide out of the engine. None 1 24 Directly above the camshaft are two lifters that the rods were connected to. Remove those lifters from the engine. None 2 25 Attached to the crankshaft is the piston. There are two bolts holding the piston to the crank. Remove these bolts and slide the piston out of the top of the engine. 10mm socket wrench 2 26 Remove the nut holding the flywheel to the crankshaft. This nut is on the outside of the engine. 22mm socket wrench 1 
27 Remove the plastic cover and the metal guard from the flywheel. None 1 28 If necessary, after the nut, plastic cover, and the guard are removed, take a rubber mallet and hit the fly wheel to loosen it up. Rubber mallet 2 29 Once it is loose, remove the flywheel and then crank shaft. None 1 30 Engine is now disassembled N/A N/A
Does your product run the same as before you dis-assembled it
- After re-assembly the engine continues to move with hand cranking as it did when we received it. There are some minor issues which would prevent it from running at this time. Damage to several gaskets (which appeared to be aged to begin with) and a lack of oil which was removed and disposed of during dis-assembly. As well several hoses were misplaced. Getting the product into a working state should be as simple as adding new oil into it, new gaskets and replacement hoses.
What were the differences between the disassembly/reassembly processes?
- The disassembly/reassembly processes were mostly the same for our group. When the product was being disassembled, our members took precaution to write down the correct sequence of events if they made any mistakes so that others would not have the same problems.
- Almost the same set of tools was used during the reassembly process. The only tool that was not needed was the rubber mallet. The tools necessary are a basic metric socket set (only the 8mm, 10mm, 12mm, 13mm, and 22mm sockets are needed), and open-end wrenches. The optional pair of pliers can also be used but the funnel is not needed any more to drain the oil from the engine.
- Our group was able to reassemble almost the entire product. The engine is reassembled and mounted back onto the frame. We are just missing a couple of hoses.
Are there any additional recommendations your group would make at the product level (operation, manufacturing, assembly, design, configuration, etc.)?
- One design change which would increase the life of the pressure washer would be to have any exposed metals either covered with plastic shielding, or coated with a highly durable paint. This would reduce rusting and other damage to the engine and washer in general, extending its operational lifetime. This would require a fairly minimal cost increase weighed against a good potential lengthening of the products life.
- During dis-assembly of the product, we noticed that several of the gaskets were in poor condition. A sturdier material for the gaskets may be in order, as well as a slight increase in the width of walls to better prevent them falling apart. Again this would increase costs slightly, but should also improve the functional life of the product.
