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Hanon Systems Internship 2017

Zach Bowling
August 2nd, 2017

Confidentiality Notice: This document contains confidential or legally privileged information. You are hereby notified that any disclosure, copying, distribution
or reliance upon the contents of this document is strictly prohibited without prior written Hanon Systems’ authorization.
Company Overview
• Tier 1 Automotive Supplier
• Full line of Climate Control & Thermal Management Systems

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A/C System Overview

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Introduction
• Education
– Michigan State University
• Major: Mechanical Engineering
• Incoming Senior (Graduating Fall 2018)
– Graduated Detroit Catholic Central in 2014

• Job
– 3rd summer working at Hanon
– JL HVAC Team Intern
• Hobbies
– Playing guitar and drums
– Camping, hiking, kayaking, etc.
– Attending as many concerts as possible

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Panel Door Leakage Investigation
• Problem
– 2/10 JL HVACs did not meet the panel door leakage spec
post Heat-Aging
– Why? How do we fix/prevent this from occurring?

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Panel Door Leakage Investigation
• Leakage Testing Process
– Seal HVAC case using duct plates and hot glue
• Pressurize case to 0.8 “H20, record air leakage (1)
– Remove plates from the duct to be analyzed
• Drive the doors to a specified “closed” position (i.e. defrost mode)
• Pressurize case to 0.8 “H20, record air Leakage (2)
– Total air leakage from the duct/door seals is the
difference between (1) & (2)

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Panel Door Leakage Investigation
• Doors shown in pure floor mode (actuator voltage = 1.58 V)
– Plenum housing removed, light bar placed underneath
– Visual gap where doors should be sealed

Left Panel Door Right Panel Door

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Searching for a Root Cause
• Hypothesis
– Hub/divider plate radius affected door position enough to cause leak
• Action
– Used aluminum shim tape to increase hub radius and sealing surface
• Conclusion
– These changes decreased the amount of air escaping, but not enough to
pass below the allowable leakage.

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Searching for a Root Cause
• Hypothesis
– Cases that failed the leak check might have parts molded in the same cavity
• Action
– Disassembled plenums for 6 HVAC cases and recorded cavity numbers for
each individual part
• Conclusion
– Cavity numbers overlapped between failing and passing cases, not enough
information to declare as a root cause

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Searching for a Root Cause

• Hypothesis
– The root cause could be pin-pointed by swapping parts from a failing case
to a passing case. If a certain part increased the leak to the point of failure,
it would most likely be the root cause.
• Action
– Individually switched 15 parts from the worst failing case to the best
passing case and performed a leak check for each one.

Panel Doors

Kinematics
Divider Plate

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Searching for a Root Cause
• Conclusion
– One of the actuators from a failing part caused the panel leakage to
spike in defrost mode. Further investigation was required to confirm
that this was the root cause.

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Verifying the Root Cause
• Hypothesis
– The feedback voltage vs. actual door position varied between actuators
and caused the leaks.
• Action
– Leak-checked 3 modes with 5 different actuators in 0.02 V increments to
map out where the doors were cracking

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Verifying Root Cause
• Conclusion
– Mapping out the door leakage vs. feedback voltage confirmed the actuator
variability theory.
Panel Door Leakage vs. Actuator Feedback
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8 Case: S2-S2
S2-S2
Leakage (SCFM)

Actuator Number
S2-S1
6
S1-S3
S5-S1
4 S1-S2
3.18 SCFM

0
1.4 1.421.441.461.48 1.5 1.521.541.561.58 1.6 1.621.641.662.392.492.592.692.792.893.313.333.353.373.393.413.433.453.473.493.513.53
Feedback Voltage (V)

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Solution Determined
• New feedback values assigned for pure floor and defrost modes
– Old values were too close to the edge of where the doors would crack
– Actuator variability caused doors on a few cases to crack sooner than others

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Solution Verified
• New feedback values allowed all 10 cases to pass the air leak
spec in both floor and defrost mode.
JL Door Leakage vs. New Actuator Feedback Values
3.5

3 3.18 SCFM

2.5
Door Leakage (SCFM)

2
Panel Doors @ 1.70 V
Panel Doors @ 3.26 V
1.5
Floor Doors @ 3.26 V
Defrost + Demist Doors @ 1.70 V
1

0.5

0
S1-S2 S2-S2 S2-S1 S3-S1 S1-S3 S4-S2 S1-S1 S2-S3 S3-S2 S4-S3
Case Set / Sample Number

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Lessons Learned
• Theoretical Data vs. Actual Door Position can vary

• For future programs, door leakage vs. actuator feedback will be


mapped out in a similar manner before a problem arises.

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Smaller Projects

• Subjective NVH Listening


– Listened to recordings for abnormalities
– Evaluated hundreds of samples

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Smaller Projects

• OEM Duct Adaptor-Plate


Leakage Testing

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Smaller Projects

• Visited the Toledo Jeep Assembly Plant


• Delivered Parts to T.M.D.
• Airflow and Water Leak Testing Assistant
• Drove Test Vehicles Back to Ford Product Development Center
• Blend-Door Variability Investigation (in progress)
• Intern Events

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Summer Takeaways

• New Department
• New Challenges
• Invaluable Experience
– Hands on lab work
– Problem solving
– Corporate communication
• Fantastic Work Environment
• Intern Classes and Events
• Great Co-Workers

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Thank You
Accelerating Innovation

www.hanonsystems.com
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