1. Missing Spray Holes in HPI HD Injector Nozzles Sponsored by: Cummins, Inc. ME 462 Capstone Design – Spring 2008 Design Team: David Graves, Aaron Huesman, Kelly McCormick, Brandon Underwood Advisor: Dr. H. A. El-Mounayri

2. Reason for Design HPI HD Injector Nozzles Partial or Missing Spray Holes Purdue School of Engineering and Technology 2

3. Main Requirements and Targets Implement non-contact method of checking nozzles for correct number of thru holes. Keep up with current production rates (3900 nozzles per day maximum.) Identify nozzle part number (ID matrix read) Pass/Reject nozzle before next manufacturing operation. Keep current manufacturing process cleanliness (4 micron tolerance). Purdue School of Engineering and Technology 3

4. Product Presentation Purdue School of Engineering and Technology 4 Insert Nozzle Here Matrix Reader Gets Part Number Part Number Sent to AutoID Controller AutoID Controller Sends Program # to Vision System Part is either “OK” or “NG” “NG” Parts are Rejected

5. Product Evaluation (Engineering Targets) Residue size under 1 µm: None Expected Footprint under 1 foot 2 : Within Range # of Operators Needed 1 or less: 1 # of Operator Miscues <=1 / 100: None with minimal training. Less than 2 hours of maintenance per month: Met Steps required to use <=2: Within Range Time added to process <=10 sec.: Under Purdue School of Engineering and Technology 5

6. Product Evaluation (Engineering Targets) Minimize cost added: $0.012 per nozzle over the first year. Number of injuries per year, zero: None expected. % of nozzles damaged during process, zero: None expected. % of incorrect identification or pass/fail, zero: None Expected. % of models capable of being tested, 100: Inconclusive but positive indications. Purdue School of Engineering and Technology 6

7. Conclusions and Recommendations Conclusions – Test unit meets all customer requirements set forth in the design phase – Test unit meets or exceeds all engineering targets. Recommendations – Automate by incorporating into assembly line – Develop case to house electrical control components – Reinforce test unit housing with stiffening agents Purdue School of Engineering and Technology 7

8. Questions/Comments Purdue School of Engineering and Technology 8