Group 3 - Homelite Fluid Pump (Gasoline Powered) - Product Explanation
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=== Mechanisms === | === Mechanisms === | ||
| − | + | INTRO | |
| + | |||
| + | ;Equations:The following are a set of general governing equations that may be applied to the analysis of the rotating | ||
| + | [[media:G3_eq1.png|thumb|center|upright=1.0|Caption]] | ||
| + | [[media:G3_eq2.png|thumb|center|upright=1.0|Caption]] | ||
| + | [[media:G3_eq3.png|thumb|center|upright=1.0|Caption]] | ||
| + | [[media:G3_eq4.png|thumb|center|upright=1.0|Caption]] | ||
| + | |||
| + | ==== 1. Crankshaft ==== | ||
| + | ;Purpose:The crankshaft creates the “up-down” translational movements in the piston by a transfer of energy through a linkage component (connecting arm). | ||
| + | ;How it Works:The connecting arm connects the crankshaft to the piston and creates alternating “up-down” translational motion by converting the rotational energy from the arm (from the crankshaft) to translational motion of the piston. On the other side of the connecting arm, the crankshaft is connected to the flywheel, which stores kinetic energy and renders the pulsating forces that create the alternating movement of the piston. Once the piston is in motion, its translational motion continues to work in conjunction with the rotational motion from the crankshaft/connecting arm. | ||
| + | |||
| + | |||
| + | ==== 2. Camshaft & Valvetrain ==== | ||
| + | ;Purpose:To properly let air/fuel mixture in and out the engine. The camshaft is an essential part of the engine because the valve movements must be timed perfectly so that fuel can be let in and out by the movement of the piston. | ||
| + | ;How it Works:The camshaft is placed above the valves within the cylinder head, and is designed to ensure that the valves open and close at the appropriate time to intake and exhale fuel. The initial downward motion of the piston is called the intake stroke – at this point, the intake valve would open. When the intake valve is open, the air/fuel mixture rushes into the cylinder. When it hits the bottom stroke, the valve closes. When the bottom stroke rises, the exhaust valve would open (to release exhaust), and the exhaust valve will close at the end of the combustion stroke. From there, the cycle is repeated. | ||
=== Design Revisions === | === Design Revisions === | ||
Revision as of 12:56, 30 November 2012
Contents
|
Product Explanation (Product Archaeology)
This component of Product Archaeology includes an overview of the product's assembly followed by additional sections which document important mechanisms found in the product and propose design revisions for product improvement.
Product Reassembly
With the reassembly of the Homelite fluid pump product, we're interested in more than just how to assemble the product. Certain information regarding the product's assembly will be introduced in the following preface to assembly before the assembly process is then presented.
Preface (Assembly)
With the assembly of this product, certain measures are of interest. In the assembly how-to guide that follows, speculation regarding the product's original assembly method and a difficulty scale will be used to document this respective information. In this section, the above-mentioned information will be formally introduced and defined.
Original Assembly Methods
INTRODUCE AND DEFINE THE NOMENCLATURE:
- [H] BY HAND
- [R] BY ROBOT??
- [O] OTHER - TO BE DESCRIBED IN REFERENCED NOTES
WE WILL PROBABLY USE A TABLE AS IN "CONNECTION TYPES" FROM GATE 2
Difficulty Scale
THIS IS THE COPIED TABLE FROM DISASSEMBLY
PROBABLY NEEDS EDITS!
A scale to accurately judge difficulty is an important part in any proper assembly. The table below (Difficulty Scale) is designed to give the user an accurate idea of each step's difficulty. The chart is divided into five different categories ranging from 1 (easily achieved) to 5 (specialist required). Any step can be placed into the appropriate difficulty based on one, or all of the following: tools required, experience and or physical effort.
| Difficulty |
Requirements | |||
|---|---|---|---|---|
| Tools/Equipment | Technical Experience | Physical | ||
|
L
E A S T G R E A T E S T | ||||
| 1 |
No tools General household tools |
Requires little to no technical experience |
Very minimal
| |
| 2 |
General mechanics tools |
Minimal |
Minimal
| |
| 3 |
Multiple tools required, used together or separate |
Moderate |
Moderate
| |
| 4 |
Requires specialty tools |
Technical Experience |
Maximum
| |
| 5 |
Requires specialty machinery |
Specialty Training |
Machine Assistance | |
Assembly Process
This section applies the previous content of this report to practical demonstration of product assembly. It is imperative that the following sections, preparation and how-to guide be read in full, and in order, for the reader to be successful in proper assembly of the product.
Preparation
Proper assembly preparation consists of thorough reading, comprehension, and execution of the following sections. Important information regarding the required tools and equipment, nomenclature, and common tasks of assembly follows.
Tools & Equipment Required
THE FOLLOWING IS COPIED FROM DISASSEMBLY
NEEDS EDITS!
Be sure to gather the Items listed in the following table:
| Item | Details
|
|---|---|
| Work Table |
|
| Bench Vise |
|
| General Equipment |
|
| General Hand Tools |
|
| Screwdrivers |
|
| Wrenches and Pliers |
|
| Sockets |
3/8 in Drive:
1/2 in Drive:
|
| Sockets Drivers: |
|
| Specialty Tools |
|
Nomenclature
Refer to the tables above for the denotation of product serviceability in terms of difficulty, and also the denotation of suspected methods of original assembly as this information will be referenced only briefly in the how-to guide. Care should be taken by the dissection personnel to be aware of personal strengths and limitations (e.g. in experience, physical strength, etc.) in completing the steps of assembly.
Common Tasks of Assembly
COPIED STRAIGHT FROM THE DISASSEMBLY
MAY NEED EDITS / ADDITIONAL INFORMATION!
- Threaded Fasteners:
- A great majority of the procedures detailed in the how-to guide involve assembling threaded connections. Whenever the part to be installed is referred to as a nut, bolt, or screw it may be assumed that the connection is threaded.
- All threaded connections in this product are right-hand threaded. To remember how to assemble a right-handed threaded connection, it may be helpful to refer to the mnemonic, "Righty-tighty, lefty-loosy," where right and left determine which way to rotate the fastener when looking at the head of the fastener. Right corresponds with rotating toward the right, or clockwise (CW), whereas left corresponds with rotating toward the left, or counterclockwise (CCW).
- Using Sockets & Socket Wrenches
- Whenever instructed to use a socket to install a fastener, it may not be explicitly stated that a socket wrench is to be used. In these cases, it is to be assumed that for a 3/8 in drive socket, a 3/8 in drive socket wrench is required (and similarly for 1/2 in drive). It is important also to be sure that ratcheting socket wrenches are set to ratchet in the proper rotational sense to remove a fastener. Become familiar with the ratcheting socket wrench before attempting to use it in this assembly process.
- The Use of Required Tool & Equipment
- It is imperative that for all tools and equipment utilized in this assembly process, the user must be fully aware of proper usage. If the user requires information regarding proper use of any tools, he/she should consult the tools' owner's manuals for proper usage procedures.
How-To Guide
| Number | Description | Procedure | Image |
|---|---|---|---|
| 1 | Install Crankshaft in Crankcase
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4172 |
| 2 | Install Valves
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
For each of (2) assemblies
|
100_4175 |
| 3 | Assemble Piston/Connecting Rod Assembly
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4177 |
| 4 | Install Piston / Connecting Rod Assembly
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
Install the piston to the crankcase
Assemble the connecting rod to the crankshaft
|
a: 100_4179 b: 100_4182 |
| 5 | Install Lifters and Camshaft
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
Note: the lobes (egg-shaped features) of the camshaft may interfere with the lifters, so the camshaft will need to be rotated to be installed. Also, the gear teeth between the camshaft and crankshaft will need to be mated for full installation of the camshaft. |
100_4184 |
| 6 | Install Crankshaft Support Bearing
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4186 |
| 7 | Install Crankcase Cover
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4187 |
| 8 | Install Side Flywheel Shroud
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4190 |
| 9 | Install Mesh Flywheel Shroud
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
pH1
|
100_4192 |
| 10 | Install Coil & Governor Mounting Plate
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4195 |
| 11 | Install Pump Housing / Bell
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
pH1
|
100_4198 |
| 12 | Install Impeller
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4200 |
| 13 | Install Engine Head
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4204 |
| 14 | Install the Carry Handle
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4208 |
| 15 | Install Exhaust Manifold
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4209 |
| 16 | Install Spark Plug and Spark Plug Wire
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
Install Spark Plug
Install Spark Plug Wire
|
100_4210 |
| 17 | Assemble Carburetor
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
Assemble Cover Plate and Contained Components
FINISH THIS LATER |
a: 100_4211 b: 100_4215 |
| 18 | Install Carburetor
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4220 |
| 19 | Install Throttle Linkage & Return Spring
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4223 |
| 20 | Install Governor Plate
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
|
| 21 | Assemble Recoil Starter
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
Prepare Spring and Hub
Install Spring/Hub Assy to Housing
Install the pull start handle
|
100_4229 |
| 22 | Install Recoil Starter Housing
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4233 |
| 23 | Install Crankcase Ventilation Tube
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4234 |
| 24 | Install Fuel Fill Cap
Difficulty: 1 Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4236 |
| 25 | Install Fuel Tank
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4238 |
| 26 | Assemble Air Filter Box
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4240 |
| 27 | Install Air Filter Box
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4242 |
| 28 | Install Oil Fill Plug
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4244 |
| 29 | Install Oil Drain Plugs
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
For each of (2) drain plugs
|
100_4245 |
| 30 | Install Pump Housing Gasket Plate
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4246 |
| 31 | Install Primer Port Plug
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4247 |
| 32 | Install Pump Drain Plug
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4248 |
| 33 | Install Pump Housing Cover
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
|
100_4249 |
| 34 | Install Base Feet
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
For each base foot:
|
|
| 35 | EXTRA
Difficulty: # Original Assembly: [R],[H],[O] Tools Required:
|
pH1
|
Challenges Faced with Assembly
Small Challenges
Substantial Challenges
Mechanisms
INTRO
- Equations
- The following are a set of general governing equations that may be applied to the analysis of the rotating
thumb|center|upright=1.0|Caption thumb|center|upright=1.0|Caption thumb|center|upright=1.0|Caption thumb|center|upright=1.0|Caption
1. Crankshaft
- Purpose
- The crankshaft creates the “up-down” translational movements in the piston by a transfer of energy through a linkage component (connecting arm).
- How it Works
- The connecting arm connects the crankshaft to the piston and creates alternating “up-down” translational motion by converting the rotational energy from the arm (from the crankshaft) to translational motion of the piston. On the other side of the connecting arm, the crankshaft is connected to the flywheel, which stores kinetic energy and renders the pulsating forces that create the alternating movement of the piston. Once the piston is in motion, its translational motion continues to work in conjunction with the rotational motion from the crankshaft/connecting arm.
2. Camshaft & Valvetrain
- Purpose
- To properly let air/fuel mixture in and out the engine. The camshaft is an essential part of the engine because the valve movements must be timed perfectly so that fuel can be let in and out by the movement of the piston.
- How it Works
- The camshaft is placed above the valves within the cylinder head, and is designed to ensure that the valves open and close at the appropriate time to intake and exhale fuel. The initial downward motion of the piston is called the intake stroke – at this point, the intake valve would open. When the intake valve is open, the air/fuel mixture rushes into the cylinder. When it hits the bottom stroke, the valve closes. When the bottom stroke rises, the exhaust valve would open (to release exhaust), and the exhaust valve will close at the end of the combustion stroke. From there, the cycle is repeated.
Design Revisions
FIGURE OUT THE ORGANIZATION OF THIS SECTION!
1. Convert Power Source From Gasoline Engine to Diesel Engine
GSEE Factor(s)
- Global
- Diesel fuel requires less refining than gasoline does therefore it can be made more simply worldwide. Changing from a gasoline power source to a diesel power source would allow this fluid pump to be sold worldwide with less concern to the refining capabilities of the area it is being sold at, thus expanding the market.
- Environmental
- Diesel fuel burns much cleaner than gasoline does reducing carbon monoxide being polluted into the atmosphere.
Advantages
- Diesel fuel has many benefits over gasoline, the first of which being diesel is more efficient to burn than gasoline. Most gasoline engines convert about 30 percent of their fuel energy into actual power. A traditional diesel converts about 45 percent (1). This means that less fuel could be used in order to create a given amount of work.
- This leads into the next advantage of diesel, since diesel engines are more efficient; they also have less heat waste. This means that the engine can run at a lower temperature than a gasoline engine of the same size can. As a result of this the engine has less stresses applied on it which increase the cycle life.
- Another benefit to diesel fuel is that it is safer than gasoline. Since diesel fuel is harder to ignite and slower burning than gasoline is will not explode unlike gasoline.
Disadvantages
- Diesel engines tend to be heavier than a gasoline powered engine which is not ideal for a portable fluid pump
- Diesel engines are slightly more expensive than a gasoline engine of equal power output
2. Convert All Fasteners to Metric
GSEE Factor(s)
- Global
- Very few countries use the imperial system and having all fasteners being metric the fluid pump would be easier to produce and maintain worldwide
Advantages
- When servicing is required, it would require less effort to determine the correct size of each fastener considering the only decision that would have to be made was the correct size, instead of unit and size
- Less expensive to produce and maintain since only one unit system of tools would be required to assemble/ disassemble
Disadvantages
- Requires redesign of all imperial fasteners
3. Convert Power Source From Gasoline Engine to Diesel Engine
GSEE Factor(s)
- Societal
- Societal demands have evolved into a desire for ease of use and adding wheel would help facilitate this demand by providing ease of transporting the pump. This would reduce the physical demand created from lifting the pump to transport it.
Advantages
- Improve the ability to transport the fluid pump from one location to another
Disadvantages
- Increased cost created from extra materials including wheels and a frame