Ford Motor Company is the world's largest producer of trucks, and the second largest producer of cars and trucks combined. Ford has manufacturing, assembly or sales affiliates in 34 countries and Ford companies employedpeople world-wide in Ford has manufacturing facilities in 22 countries on 5 continents, with 87 plants in North America and 41 in Europe.
A fuel-rail on their 5. These failures naturally created some concern. Fuel-Rail System Figure 2: Fuel-rail system leak after test.
Potential Consequences and Risk Ford was concerned about repeated lab failures even though the product seemingly operated problem-free in the field.
Properly analyzing failures could be the difference between a costly recall or no recall. One of two things was flawed: In order to restore confidence in the fuel-rail and gain peace of mind, the Ford technicians needed to analyze their test to see if their issue was over-testing or a faulty fuel-rail.
After reviewing all of the data compiled from various parts of the engine, we decided to concentrate specifically on the engine head.
However, the data from Ford had a broad range spectrum of Hz, and using the fatigue damage import function required an So, the team band limited the data to Hz. Focusing on this range, the team proceeded. G RMS values for components of fuel-rail system at frequency range Hzfuel-rail system.
The S-N curve showed that the lab tests were significantly over-testing the fuel-rail system. S-N curve for fuel-rail system—actual data. After extrapolating the S-N curve to the 2. But the Ford lab technicians were observing failures in the lab during the hour durability standard test which ran at the 2.
The Solution — Part II The dynamometer that was used by Ford to test the fuel-rail system significantly over-tested the product. And it tested the fuel-rail system with a completely different kind of environment than it would experience in the real world. In their search for a better test than that which over-tested the product, the technicians wondered whether to run a series of sine tests at various known resonances or to run a random test across a known frequency range.
Due to the significant resonances at a number of key locations on the fuel-rail, the technicians considered the possibility of testing with a series of sine tones having large amplitudes at the key resonant frequencies observed in the engine and fuel-rail system.
The problem with this proposed solution was that the engineer was saddled with several sticky questions, including which sine tones should be used and with what amplitudes. In addition, the possibility of the resonances on the fuel-rail shifting and changing when mounted to the engine would make it difficult to test the true resonances of the fuel-rail system.
In light of these concerns, the sine test option became less favorable and was not used.
The team already had a waveform containing the engine head vibration patterns which caused significant resonances in the fuel-rail. Further, the team had already developed an S-N curve, which afforded an approximation of the m value the critical parameter in fatigue damage.
The target life and test duration were set to hours. With respect to the fuel-rail system, the resultant test gave the fuel-rails a life-dose of fatigue damage that they would experience in the field.
This meant if the fuel-rails survived the lab test, they could be expected to survive in the field. In addition, with an accurate m value, the engineers could shorten the test duration while keeping target life the same.
The FDS test would apply the same amount of damage a life-dose but in a shorter amount of time without over-testing the product. Less G RMS, same damage.
Conclusion The S-N curve for the fuel-rail—built from data and then extrapolated—indicated that the fatigue life of the fuel-rail was around 10, hours for a vibration test at 2.
Ford utilized a standard that required the fuel-rail system to survive a disastrous waveform test for a minimum of hours, based on the kind of environments that the engine was expected to encounter in real life.
Ford also utilized a durability standard that required a product to survive hours of similar testing.Ford Motor Company was founded in , in the United States of America, by Henry Ford and eleven other investors.
By , the business began to prosper. Following disagreements with the other investors, Henry Ford and his son, Edsel Ford bought the shares of the investors and became the sole owners and decision makers of Ford .
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