Group 19: Gate 2
Product Dissection Plan
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.
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.
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.
Figure 1:
| STEPS | TOOLS | DIFFICULTY
(A/B) |
|---|---|---|
| Removed filter cover | Philips head screwdriver | 1/1 |
| Removing casing beneath filter | Philips head screwdriver | 1/1 |
| Removed air intake, revealed springs with black caps and valves | Philips head screwdriver | 2/1 |
| Removed upper casing | 10mm socket wrench | 2/1 |
| Removed carburetor | N/A | 3/1 |
| Removed alternator | 8mm socket wrench | 2/2 |
| Removed outside casing over chain from crankshaft to camshafts | 8mm socket wrench
10mm socket wrench |
3/2 |
| Removed more components of crankshaft chain | 14mm socket wrench | 1/1 |
| Removed the outside casing of the transmission | 10mm socket wrench
14mm socket wrench |
3/2 |
| Recorded an experimental video – shows the rotation of the crank shaft results in rotation of the air flow and exhaust flow regulator | Camera | 1/1 |
| Removed a piston that was adding tension to the spring on the side of the engine | 10mm socket wrench | 3/1 |
| Removal of shafts regulating air flow through removal of the piston | 8mm socket wrench | 2/1 |
| Loosened and removed nuts & bolts from main body | 10mm socket wrench | 1/1 |
| Removed torx screw from front of engine to disassemble the upper half | Torx screwdriver | 2/1 |
| Removal of water pump | 10mm socket wrench | 3/1 |
| Further removal of bolts | 10mm socket wrench | 1/1 |
| Removal of radiator hoses | Removal by hand | 1/1 |
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.
Figure 2:
| STEPS | TOOLS | DIFFICULTY
A/B |
|---|---|---|
| Removed bottom plate, exposing the pistons, the transmission and the crankshaft | 10mm socket wrench | 4/2 |
| Recorded an experimental video of how we think the engine works | Camera | 1/1 |
| Removed interior bolts, making way towards the transmission | 13mm socket wrench | 3/2 |
| Removed radiator fluid filter | 10mm socket wrench | 2/2 |
| Removed transmission: revealed a system of gears that dictates the motion of the pistons which control the motion of the motorcycle | 14mm socket wrench | 4/2 |
| 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. | N/A | 1/1 |
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.
Causes For Corrective Action
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.
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.
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.
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.
