fsae mis 2016 maclean-fogg fastener challenge
TRANSCRIPT
![Page 1: FSAE MIS 2016 MacLean-Fogg Fastener Challenge](https://reader036.vdocuments.mx/reader036/viewer/2022081419/62a0e325e3c82945241cfaee/html5/thumbnails/1.jpg)
FSAE MIS 2016
MacLean-Fogg Fastener Challenge
![Page 2: FSAE MIS 2016 MacLean-Fogg Fastener Challenge](https://reader036.vdocuments.mx/reader036/viewer/2022081419/62a0e325e3c82945241cfaee/html5/thumbnails/2.jpg)
Intake Manifold Fastening
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The Problem
2
• Originally:
– Bolt intake manifold directly to engine head
– Very tight packaging in engine bay
• Issues
– Stripped threads in engine head
– Bolts dropped into intake ports
– Bolts dropped into engine bay
– Time lost dealing with the above issues
![Page 4: FSAE MIS 2016 MacLean-Fogg Fastener Challenge](https://reader036.vdocuments.mx/reader036/viewer/2022081419/62a0e325e3c82945241cfaee/html5/thumbnails/4.jpg)
The Solution
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• Double o-ring seals on each runner mating to an “ intake flange”
– Designed for up to 100 psi seal
• Intake flange bolted to engine and sealed with o-rings
– Removed very rarely
• Quick release pins
• 2 s-shaped “ mustache” armatures to restrict upward movement of intake
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The Solution
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Quick release pinIntake flange
“ Mustaches”
O-ring bore
Interface to
engine intake
port
5 X bolt to engine
![Page 6: FSAE MIS 2016 MacLean-Fogg Fastener Challenge](https://reader036.vdocuments.mx/reader036/viewer/2022081419/62a0e325e3c82945241cfaee/html5/thumbnails/6.jpg)
Further Design
5
• How does one retain the “ mustaches” and the manifold?
• Previous designs
– Bike seat clamp to hold mustaches down: no loose parts, but difficult to adjust clamping force
– Quick release pin through flange and a cylinder pressed into mustache
– Quick release pin through a rectangular block bolted to mustache
![Page 7: FSAE MIS 2016 MacLean-Fogg Fastener Challenge](https://reader036.vdocuments.mx/reader036/viewer/2022081419/62a0e325e3c82945241cfaee/html5/thumbnails/7.jpg)
Comparison
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Press and Pin
Exact clamping height, but no axial
retention of mustache, could vibrate
loose
Block and Pin
Fully constrained, simpler to
manufacture
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Success
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• No intake leaks at the engine-intake interface for this design
• No bolts/ o-rings from assembly dropped into engine bay or intake ports
• Fully constrained design
• 5 minute assembly/ disassembly of intake from car
• Backwards and cross-compatible with multiple intake manifold designs
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Design Implemented
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Tight packaging
in the engine bayIntake manifold
retention system on car
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Lessons Learned
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• Reduce parts and tools required to
assemble
• Reduce alternative assembly methods
– Only 1 “ right way” to assemble
• Constrain and retain within the
requirements of the part
• Iteration is key
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Future Improvements
10
• Integrate mustaches into intake manifold
– Further reduce number of parts
• Permanent pin retention to flange
– Reduce loose parts
• Constrained bolts on intake flange
– Reduce loose parts
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Contact Information
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Thank you!Sarah Behringer, Team Captain
Sam Wormuth, Team Captain
Jonathan de la Fuente, Powertrain Lead
Alexius Wadell, Intake/ Exhaust Lead
Contact:
TeAnn Nguyen, Systems Engineer
480-466-9595