Group 9 - GM Inline Four Cylinder Engine - Request for Proposal
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Gate 1: Request For Proposal
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Work Proposal
Approach for Disassembly
The product assigned to Group 9 is a 2.2 Liter GM inline 4 cylinder engine. Group 9 plans on collaborating with group 24 who have the same engine to work on. The planned components for dissection are the belt drive system, camshaft and crankshaft. Group 24 has revealed they will work on the headers and pistons. As a group, step by step photographic documentation will be taken throughout the disassembly/reassembly processes. In addition to the documentation, clear labeling of all the components will ensure a smooth reassembly process. The engine components are to be dissected using a combination metric wrench set, pliers and Allen wrenches. English/customary units will not be necessary because automobile engines are made to internationally compatible therefore the fasteners are in metric. Estimated time for dissection is approximately 3 to 4 hours spread over 2 weeks. Along the way of the project, group 9 expects to do some outside research because overall the group is not experienced with engines. Four of the five members of group 9 do not have previous knowledge of the function of engine components, where components are located, and how to disassemble/reassemble. Another challenge will be working and coordinating efforts and schedules with group 24. Group 24 must disassemble their components before group 9 can begin the disassembly process. Space in the lab will also be a challenge, as the engine is fairly compact and workspace is limited. Reassembly will be challenging due to the complexity of the components.
Capabilities and Shortcomings
As a whole each member of group 9 has certain strengths to contribute. Bryan is the only person on our team with knowledge and experience with engines, the components that are part of the engine and disassembling/reassembling. Richard is experienced in 3D modeling with CAD and Pro Engineer. Michael has HTML knowledge and is quick at learning coding and related skills. Christine has experience as being leader of a group. Adi is always available and quick to respond and initiate conversation via e-mail and telephone. Despite the strengths group 9 still has shortcomings. All members in Group 9 except for Bryan have no prior knowledge of how engines work. As a group it is imperative to further develop knowledge of the internal combustion engine, dissection and assembly processes. Along with research of the internal combustion engine it is also important to know how all the parts function, if the engine was intact and working. Regardless of this shortcoming group 9 has a strong interest in the subject and view the assignment as a challenge. Ideally the interest in the subject will stimulate progress.
Management Proposal
Group Roles
The group will work on the project together so that all members will have a chance to edit the wiki, solid model, disassemble, etc. The purpose of the roles is simply to make certain people accountable for certain part of the project. Roles are expected to overlap once the project is underway, but accountability will remain as agreed upon by the group. As stated in the work proposal, the members in group 9 are expected to help one another with each part of the project. Team work is a major part in successfully meeting the challenge posed. Working together will result in an efficient outcome. Group 9 are efficient individuals but have not worked with one-another previously. To resolve this conflict each member is responsible for certain aspects of the project but will also be available for extra help and questions when another member is unsure of something. The biggest conflict group 9 will face is meeting regularly with all members present due to the differences in schedules and living arrangements. All members except Bryan live on campus so meetings will be held on campus. Group 9 has decided to meet every Wednesday at 5:00 p.m. to ensure the conflict is resolved.
"Project Manager" - Christine Menton
- In charge of keeping the group on task and makes sure that everyone adheres to the plan (proposal, gannt chart, etc)
- Leads general meetings and breaks up tasks among the group so the schedule is maintained.
- Makes sure group work is presentable and formatted well (final editor).
- Leads the group in gates 1 and 5.
"3D Modeling and Tech Expert" - Richard Lipcyznski
- Leads the team in the 3D modeling of the parts.
- In charge of the component listing/summary.
- Leads the group in analyzing the product and formulating design revisions.
- Leads the group in gate 3.
"Dissection Leader" - Bryan Papaj
- Leads the group in dissection and reassembly.
- Makes sure group gets to the lab and that everyone stays informed as to what were doing.
- Makes sure parts are labeled or easily identified so reassembly will be easier.
- Takes pictures of all the parts.
- Leads the group in doing Gates 2 and 4.
"Wiki Leader" - Michael Huffman
- In charge of learning about how to edit wiki, embed pictures, format, etc.
- Instructs the group how to properly use wiki.
- First editor of the content published on wiki page.
- Makes sure wiki is constantly updated with group progress.
"Communication Liaison" - Adityavikram Rajawat
- Contact point between our group and the professor/teaching assistants.
- Takes notes at group meetings and sends information through e-mail.
- Keeps group connected on days when members are missing from meetings.
- Takes over as Project Manager in Christine's absence.
- Ambassador to other groups, specifically group 24.
- Ensures group 24 removes their components so group 9 can begin disassembly.
Meeting Info
As stated in the group roles, group 9 plans to meet at least once a week on Wednesdays at 5:00 p.m. Group 9 We will meet in the classroom and go over to the library in Capen or computer lab in Bell Hall. This meeting will be to review group progress and assess current standings. Tasks for the upcoming week will be divided up amongst the group by the Project Manager (Christine), or in her absence the Communication Liaison (Adityavikram). Notes for the general meeting will be taken by Adityavikram and sent out to everyone by e-mail so there is no confusion as to what everyone is doing. The general meetings will be supplemented by additional meetings when needed. Group 9 plans to begin dissection starting on Monday October 12, 2009. Lab and dissection progress will be cataloged during these meetings.
Work will be managed directly using a Gantt chart which tracks progress and deadlines. Completed tasks are in blue.
Initial Product Assessment
Intended Use of the Product
The intended use of this product is to take air and fuel in and turn it into work. The work will then be transmitted through the transmission to the axles in order to drive the wheels of a car.
Is the product for home or professional use?
This product is intended for both home and professional use. The GM 2.2 L engine is made specifically for use in an automobile. Automobile engines are used by home owners and professionals alike. Homeowners maintain their engines to a certain degree(oil changes, air filter). Professionals are more knowledgeable of engine maintenance and can diagnose and fix larger problems with engines.
What are the different functions of the product?
The main function of this product is to produce mechanical work. This is its only function.
How the Product Works
How do you think the product works?
The engine takes electrical energy, air, and fuel in. It then compresses the fuel and air mixture, ignites it, which makes it combust into thermal energy, which does work on the pistons crankshaft. This work done on the crankshaft is relayed to work out of the system.
What types of energies are used?
The engine uses electrical, chemical, thermal, and mechanical energy in it's function.
How are these types of energies transformed and modified?
The process starts with electrical energy in the spark plugs. Air and fuel inside the cylinders is compressed and ignited which creates thermal energy. The extreme pressure inside the cylinder forces the pistons down which turns the crankshaft. The energy is now mechanical which can be used to power the drive shaft. Due to the internal combustion for the small amount of fuel intake, there is a much greater output in terms of mechanical work.
Product's Functionality
Is the product currently functioning?
The product is not currently functioning. An engine requires many other outside parts to operate. This system of parts will not available to us throughout the project.
If there are any problems, what do you think they are coming from?
Since we do not have all of the parts necessary to even start the engine it is clearly seen that it would not function anyway. The engine block itself has a large hole cut out of the side of the piston wall. If the pistons are not allowed to compress the gas/air mixture the combustion would not occur. There are also many other parts cut open into cross sections such as the oil filter. Since those parts do not form a closed system the engine would have too many problems and therefore fail to operate.
Product Complexity
How complex is the product?
Defined by the Merriam-Webster Dictionary complex is a whole made up of complicated or interrelated parts. Based on this definition the GM 2.2 L 4 cylinder inline engine is fairly complex. It is complex because of the multiple number of interrelated components, advanced systems and complicated processes. Group 9 estimates that there are at least 5 different systems within the engine and roughly 100 individual components including fasteners.
For the individual components how complex are they?
The individual components are not very complex by themselves. Most of the components are just metal or plastic pieces joined together in an elaborate way to create the complex system that is the engine. The form of the engine is determined by the function it creates.
Materials Used in the Product
What materials are clearly visible?
This product is primarily composed of various metals. It is mostly made of steel, hardened plastics and aluminum. Steel is easily recognizable because it has a rough finish, poor shine and is very heavy. Hardened plastics have a dull finish and rather light but durable. Aluminum has a shiny and smooth finish, is relatively light but at the same time strong. Rubber and copper are used in the wires for insulating and conducting properties respectively.
What materials do you think are not visible but present?
Group 9 can assumes the above materials of steel, aluminum, plastic and rubber are present but not visible. Some examples based on previous knowledge are:
- Engine block is steel
- Pistons are aluminum
- Pulleys are hardened plastics
- Gaskets are rubber for sealing purposes
Product Satisfaction
If you had to use this product, would you be happy with it?
It is unsure to say if group 9 would be happy to use the GM 2.2 L engine. Since the engine does not function there is no way of knowing if the engine is efficient, quiet or noisy, and also substantial if placed in an automobile. Though the parts given are in fairly good condition and if the engine was working properly, group 9 would be happy to work with it as it is a rather well designed engine for mass produced automobiles.
Is the product comfortable to use?
The product is comfortable to use in a car. Standalone, this product is not very useful because it is a car engine. Cars are a very comfortable mode of transportation (especially compared to walking) and the engine just supplies work to it. The engine in no way makes the trip uncomfortable. It can however be inconvenient when it doesn't work properly as the car will not function without it and will require maintenance.
Is the product easy to use?
This product is easy to use in a car, but again on its own this product is rendered useless. Starting a engine in a functional car is accomplished with a turn of a key. Using an engine is a very easy way to power a car and makes long distance transportation far more easy and convenient.
Does the product require regular maintenance? If so is the product easy to service?
This product does require regular oil change as engine oil has limited life, after a certain point it starts losing lubricating qualities and carbonizes which makes the engine contaminated with carbon deposits that significantly shorten the engine's life. Also the cooling system requires regular maintenance. If there are any major problems the engine can be serviced by professionals. Thus making the servicing of the engine fairly easy to the owner of the vehicle but it can be expensive and time consuming at times.
Alternatives to the Product
What other alternatives to your product are there? How do these alternatives compare?
The engine is quite standard but there are countless numbers of other engines out there. There are many alternatives to an engine such as the number of cylinders, the geometry of the block, or the type of ignition system but the two major engine types in use are spark ignition (gasoline engine) and compression ignition (diesel engine) which use different types of fuel. The main difference between a gasoline engine and a diesel engine is the fuel used though both engines have a relatively similar combustion cycle.. Different fuel type engines also include include hybrid, electric and bio-diesel.
What are the differences in cost?
Other fuel type engines such as a hybrid are usually more in cost compared to a gasoline engine. However, the hybrid engine will save more money over a longer period of time because their needed fuel is much less. Engines with more cylinders will be able to produce more power, and also have more fuel intake. With more power comes more cost. However, automobile engineers are making more powerful engines smaller and with less costs. The normal however still follows larger equals more power.
What are the advantages?
There are different performances for different cylinders. The engine given to group 9 is a 2.2 liter inline 4 cylinder but there are 1.6L, 2.4L, etc., all with 4 cylinders. Advantages of a larger engine or better performing engine are increase in output in the form of speed/torque. The 2.2L is a good blend of performance, efficiency and cost.
What are the disadvantages?
The disadvantage of a more powerful engine is usually less fuel efficiency.The efficiency of the diesel engine is higher than the gasoline engine because of higher compression ratio, and because the temperature of combustion in a diesel engine is much higher. A gasoline engine cannot have the same compression ratio as a diesel engine, because fuel and air are mixed before they reach the cylinder, and they would explode before the piston reached the correct firing position For example the engine powering a truck gets a lower EPA estimated miles per gallon rating than an engine in a small sedan. For a hybrid/electric the costs of the engine are much higher due to the technology inside. Hybrids and electric cars fit within the trend of lower performance of a gasoline or diesel.
