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The aim of this assignment is to provide students with an opportunity to experience the process of carrying out a design project. Successful completion of this coursework requires the synthesis of parameters which will affect the design solution.
As part of the design process an automotive manufacturer, such as Ford, will rigorously attempt to determine the full range of operating conditions for an engine fitted to a standard production vehicle. They will go to great lengths to ensure that every system, assembly and component used in a vehicle is ‘fit for purpose’. When a power plant is subjected to conditions other than those for which it was designed/developed, systems which were ‘fit for purpose’ may no longer perform adequately due to new or increased demands.
The Ford Zetec engine is found in a range of production vehicles. All standard Zetec engines employ a ‘wet sump’ type lubrication system (see ‘wet sump’ system description). ‘Wet sump’ systems are sometimes replaced by ‘dry sump’ systems (see ‘dry sump’ system description) when an engine is modified for use in high performance, motorsport applications.
You have been commissioned to design a suitable dry sump pan and oil pickup adaptor for a Ford Zetec engine, as the customer intends to fit the engine into a vehicle which will be used in motorsport (track) competitions.
The following design parameters have already been established:
• A separate, external, oil pump will be added to the system to scavenge oil from the sump pan and deliver it to a remote oil reservoir/tank. You are not required to design or specify the oil pump or the oil reservoir/tank.
• The oil will be fed from the reservoir/tank back to the standard oil pick-up point, where the original oil pump will be used to deliver the oil to the lubrication points within the engine.
Initial market research has established the following customer requirements:
Customer requirement Requirement importance rating (out of 10)
The product should be light weight 8
The product should be easy to install (initial set-up) 5
In the event of a roll-over, the engine should not be flooded with lubricant 9
The product should be low cost 7
The product should allow easy/fast access for servicing/maintenance 7
The standard Zetec unit (with original sump) will be available for inspection in the Engine (Heat) Lab. If you require access to the engine, please pre-arrange this with a member of the Technical Support Team.
The ‘Wet Sump’ System
These systems use a sump pan to store/collect and to a limited extent cool oil. The oil is then pumped from the sump pan, through various galleries, to lubrication points throughout the engine (some engines will divert the oil through a heat exchanger before delivering it to the lubrication points). Gravity causes the oil to drop back down through the engine where it collects in the sump pan. The oil recycles as the process is repeated.
The ‘Dry Sump’ System
A ‘dry sump’ system is the name given to a lubrication system in which any oil which falls into the sump pan is scavenged (pumped) into a remote storage reservoir/tank. Some systems will then pump the oil from the remote reservoir/tank directly to the lubrication points throughout the engine, eliminating the need for the standard oil pump and oil pick-up point. Other systems will direct the oil from the reservoir/tank, back to the original oil pickup point which would have been used on the standard ‘wet sump’ lubrication system. From this point the oil is pumped up to the engine’s lubrication points by the original (standard) oil pump.
Note: All information used in your report must be properly referenced using the Harvard Referencing System
Remember, you will be graded on each stage of the design process and not just the final design/solution.
Maximum word count – 3000 words
Assignment Brief / Task
Using appropriate methodologies and ‘tools’, arrive at a design solution for the dry sump pan and a suitable oil pickup adaptor. Detail each stage of the design process in a report.
The main stages of an appropriate design methodology are outlined below along with the marks
which will be attributed to each stage:
a) Problem identification/ understanding the need. This section should include a Quality Function Deployment (QFD) analysis.
(20marks)
b) A Detailed Design Specification which defines targets for the design prior to any creative design activity.
(20 marks)
c) The development of concept designs.
(15 marks)
d) A design isolation exercise which objectively evaluates the concept ideas with the aim of establishing an optimum or preferable solution. This may or may not include ‘controlled
convergence’.
(20 marks)
e) Documentation of the final design, including a full description, a solid model and a
technical drawing (BS 8888).
(15marks)
f) Evaluation framework. This should include recommendations for how the design would be tested/evaluated and not an evaluation of your design activity or report.
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