A methodology for the design optimization through integration: FCU bracket and FIP housing integration and achieving the system targets
2022-01-0766
03/29/2022
- Event
- Content
- The increasing demand for higher specific power and the need for weight reduction and decrease of emissions have become the driving factors of product development in automotive market today. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. One of the approaches to optimize the design is through the process of integration which involves integrating the functional elements of two or more components into one and achieving a reduction in weight and cost without impacting required performance. This paper explains a similar approach followed as a part of Design and Development of 1.5 L, 3 Cylinder CRDI Diesel Engine for a new vehicle platform, developed for automotive passenger car application. Two components of the fuel injection system - fuel injection pump (FIP) housing and fuel control unit (FCU) bracket are integrated into one component. The paper discusses the design methodology, integration of classical methods, and verified through CAE simulation to ensure the required targets of modal analysis and strength analysis are met. Simulation results and actual measurement results are discussed in detail to show the effectiveness of an integrated approach used in this development program. Tools like DFMEA, DFMA etc. are used along with value engineering concepts to make an efficient and cost-effective product to the end customer with minimum iterations in reduced cycle time.
- Citation
- vinaya murthy, v., Rengaraj, C., and Dharan R, B., "A methodology for the design optimization through integration: FCU bracket and FIP housing integration and achieving the system targets," SAE Technical Paper 2022-01-0766, 2022, .