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COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT AND PROJECT

HOSTING COMPANY ANAGAW GETACHEW TURNO


HOUSE
PROJECT TITLE: DESIGN FUEL INJECTOR TESTER
Time Duration: -Three Months

Debre Berhan, 2015 E.C


DEBRE BERHAN UNIVERSITY INTERNSHIP REPORT 2015E.C

Prepared By: ID NO.


SIMACHEW SHITU 2549/11

SUBMISSION DATE: − 12/06/2015E.C

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Declaration
First of all, I express our heartiest grate fullness to Almighty GOD for his countless blessing,
which enabled us to complete this successfully. This final internship document is an independent
work of students that take internship program in the hosting company of Anagaw Getachew
Turno House Enterprise. All writings in this document contain things that are done by our effort
under the guidance of our company supervisor Mr. Eshetu and Mr. Alemtsehay and our adviser
Mr. Ashenafi, family, fried

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Acknowledgement
In this document preparation I would like to thank and express my grateful gratitude to DEBRE
BREHAN Institute of Technology for giving this chance to develop my practical skills,
ANGAW GETACHEW TORNO HOUSE for allowing us to work in Motor and Manufacturing
class and their great support in the day-to-day activity by a good respect and appreciation,
faculty and company advisor for their valuable comments, suggestions, constructive criticisms,
and great support for my project work. In addition to these I heartily thank my families and
friends for their financial and moral support.

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Abstract
The exponential development in technology and industry boosted the productivity of industries
to such unprecedented level that caused an increase in the number of automobiles produced for
both industrial and personal use.
As the amount of fuel is limited more studies are directed to reduce the fuel consumption of the
automobile. One way of reducing the fuel consumption is the use of efficient and accurate fuel
injector and to ensure that the fuel injector is efficient and accurate the fuel injector tester is quite
handy tool to provide that platform. Another aspect is the environment concern that the emission
of unburn fuel, CO and Co2 can be reduced by using accurate and efficient fuel injector.
The purpose of our project is to construct a design fuel injector tester to verify if a fuel injector is
accurate to the manufacturer standards or not.

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Contents
Declaration......................................................................................................................................II
Acknowledgement.........................................................................................................................III
Abstract..........................................................................................................................................IV
CHAPTER ONE..............................................................................................................................1
1 BACKGROUND OF THE COMPANY......................................................................................1
1.1 Company brief history............................................................................................................1
1.2 Vision.....................................................................................................................................1
1.3 Mission...................................................................................................................................1
1.4 How you get into the company...............................................................................................2
1.5 Section of the company I have done......................................................................................2
1.6 Tasks I have been executing...................................................................................................3
1.7 Engine shop............................................................................................................................3
1.8 Service Render Work Shop....................................................................................................4
1.9 Body Shop..............................................................................................................................4
1.10 Maintenance and Repairing Shop.........................................................................................4
1.1.1 Electrical shop..................................................................................................................5
1.1.2 Manufacturing Shop.........................................................................................................6
1.1.3 Machines Found in the Work Shop..................................................................................6
1.1.4 Challenges and Problems I Have Been Facing While Performing Tasks........................7
Measures Have Been Taken to Overcome the Challenges..............................................................7
1.1.5 Work Flow in The Section...............................................................................................8
CHAPTER TWO.............................................................................................................................9
2 OVERALL BENEFITS GAINED FROM INTERNSHIP...........................................................9
2.1. Benefit gained from practice skill.........................................................................................9
2.2. Benefit gained according to theoretical knowledge skills.....................................................9
2.3. Benefit gained in terms of improving my interpersonal communication skills..................10
2.4. Benefit gained in terms of improving my team playing skills............................................10
2.5. Benefit gained in terms of improving my leadership skills.................................................11
2.6. Benefit gained in terms of work ethics looking at Work Ethics Skills...............................11
2.7. Entrepreneurship skills........................................................................................................12
CHAPTER THREE.......................................................................................................................13
3 INTERNSHIP PROJECT...........................................................................................................13

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3.1 Title of the project................................................................................................................13


3.2 Introduction..........................................................................................................................13
Parameters that affect the performance of fuel injector.................................................................13
3.3 Operating principles of fuel iinjector tester stand machine..................................................15
3.4 Statement of the problem.....................................................................................................16
3.6 Objective..............................................................................................................................16
General objective........................................................................................................................16
3.7 Scope....................................................................................................................................17
3.8 Significance.......................................................................................................................17
3.9 Limitation.............................................................................................................................17
CHAPTER FOUR.........................................................................................................................18
4 LITREATURE REVIEW AND METHODOLOY.................................................................18
4.1 LITREATURE REVIEW........................................................................................................18
4.2 METHODOLOGY..................................................................................................................19
4.3 DESIGN OF INJECTOR TESTER.........................................................................................20
Cost Analysis..............................................................................................................................36
CHAPTER FIVE...........................................................................................................................37
RESULT AND DISCUTION........................................................................................................37
CHAPTER SIX..............................................................................................................................43
5 CONCLUSION AND RECOMMENDATION.........................................................................43
5.1. Conclusion...........................................................................................................................43
5.3 RECOMMENDETION........................................................................................................44
REFERENCE................................................................................................................................45

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CHAPTER ONE

1 BACKGROUND OF THE COMPANY

1.1 Company brief history


Getachew Turno House company found in kossober city which is 450 KM far from Addis
Abeba. It established in 1995 E.C by Anagaw Getachew with initial capital not more than
200,000 birrs. The company covers an area of 2000 meter squares. Currently The number of
workers becomes more than 25. This company gives different services like brake services,
battery services, body painting and automotive engine services.

1.2 Vision
 To be one of the open three up to five branch in Amhara region for after 20 years.
• Responsibility
• Transparency
• Giving dynamic service for customer
• Preparing for change
• Working with educated knowledge and transparency
• Safety
• To be the leading Public Transport service provide in the city

1.3 Mission
To ensure satisfaction of the society by maintaining and overhauling different models of
vehicles with better efficiency, quality and at lower cost.
To increase manufacturing capacity and capability for tools, spare parts and auxiliary required
for overhaul and Assembly activity.
• Giving comfortable, modern, active transportation service.
• Working with other means of transportation to give comfortable, active service for people.
• Giving confidential automotive technology service.
• Building company that produce spear part of automotive.

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• Automotive engineering vehicle spear part production and decreasing (reducing)


outgoing money.

1.4 How you get into the company


Choosing a company which can fulfil my interest and which is related to mechanical
engineering studies was not easy task for me. After collecting information from my seniors,
teachers, I decided to join in to ANAGAW GETACHEW TORNO HOUSE. In Anagaw
Getachew Torno there was almost everything what I need. So finally, I decided to stay four
months of intern ship program in Anagaw Getachew Torno House.

1.5 Section of the company I have done

The section I was working is under equipment maintenance room, auto mechanical maintenance
and motor maintenance class. I was working as auto mechanical and Manufacturing for three
months starting from February up to October 30. I try to identify materials which are appropriate
for my intern ship.

Figure Open, closed and combination wrenches

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1.6 Tasks I have been executing


ANAGAW GETACHEW TURNO have commonly 3 different blocks. Each block has their own
tasks. But mainly I joined and worked at one of the blocks which is called service rendering. In
this section I acquired more knowledge about servicing different models of trucks, repairing and
over hauling engine components for heavy duty truck engines, light duty truck engines and
public service cars like mini buses.
1.7 Engine shop
As the name indicates the section works on the engine system and give service on changing
injector pump, fuel line, fuel system, fuel filter and changing for engine smoke and valve
adjustment and checking and inspecting engine.
The engine shop is classified in to two major classifications
1. Minor engine shop
2. Major engine shop
1.Minor engine shop
In this shop the service is not that much complicated and the first approach to some problems
that face the vehicle for example engine smoking and some leakage and also lubrication
problems without disassembling the pars.
Tasks taken for maintenance are engine oil, engine oil filter, cooling system (water pump
problem), heater system (glow plug), engine coolant, drive belt, air cleaner, valve clearance, fuel
injector, intake manifold and exhaust manifold problem and additionally radiator cap problems
like pressure and vacuum cap.
2.Major engine shop
This one take very complicated operation to solve the problem and engine disassembling because
in this case the problems are not easy like engine power losing, engine knocking, engine oil
consumption and fuel consumption additionally engine starting problems.
Some tasks are: changing fuel line and fuel system, valve timing and clearance adjustment, major
to minor overhauling, changing injector pump, some other engine diagnostics.
N.B engine overhauling is repairing the damaged part of the engine like connecting rod, cylinder,
piston head and others by using lath machine, milling machine and other necessary machines.

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1.8 Service Render Work Shop


In this work shop there are four type of work section. These are,
 Body and welding workshop
 Maintenance and repairing shop
 Electrical shop
 Manufacturing shop

1.9 Body Shop


Body shop is a type of service render shop. In this shop there are a lot of activities performed.
Among thus, washing, grinding, painting and welding are the main activities. Car body consist
the following components.
Fender, Mud guard, Foot step (rocker panel), Roof panel, Door hinge, Spooky outside door
handle, regulator gear, Center, Pillar, Target panel, Hood (engine cover), Top caw Vessel, Reel,
Dash board (instrument panel), Cart, Sill panel

1.10 Maintenance and Repairing Shop


In this shop different auto mobiles are maintained and repaired if there is any problem detected
by the mechanic or operator. Because of its vast working systems and most related to our study, I
have spent most of my intern ship period in this shop. During those times I know the
maintenance of engines and their working mechanisms and also the working principle of
transmission, gear box, differential, suspension system, propeller shaft, cooling system,
lubrication system, ignition system, and electrical system. I tried to point out re-conditioned
components of the engine and I know their failures and their remedy. By analysing the creation
of power in the engine and types of strokes [intake, compression, power and exhaustion system],
I had developed my awareness regarding to my study. I also knew mechanisms of ignition
system, lubrication system and cooling system with their maintenance methodology. In addition
to this, I saw how much designers put intense concern about vibration in auto mobiles. Therefore
five sections are here. These are service section, rebuild section, electrical shop, body and paint
shop and last one manufacturing shop.
Regular inspection programs (equipment condition monitoring) Means paying attention to
what the machine is telling you.

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 Checking gauge readings


 Checking their performances
 Assessing smoke, heat, leaks, and loose parts.
 Listening for changes in the noise levels
Maintenance and repairing shop have the following work execution steps
 Inspection of the problem
 Disassemble part of the vehicle which is going to be maintained. Maintaining includes
lubrication, air cleaning and tightening.
 Maintain (including lubrication, air cleaning and tightening)
 Wiping treated spare parts
 Assemble
Check if there is any miss function
Generally, there are two ways of service in this shop. These are;
Scheduled (preventive) maintenance: - this is normal way of service that is the vehicles are
serviced periodically. It includes express service, maintenance service, repair service and
component service. Some of advantages of preventive maintenance are
 Allows scheduling down time
 Prevent major failures
 Maximize parts re usability
 Optimize equipment life to keep machine running
 Increase machine resale value
Unscheduled (break down) Maintenance: -any kind of service that is not periodically serviced
it included in the category like the vehicle injured by accident.
Used for unnecessary replacement of part is avoided in addition lower downtime is required.

1.1.1 Electrical shop


In this shop, most of a vehicle`s electrical systems are maintained and replaced by the
new ones. Maintenance of electrical systems contains,
 Filling the battery with proper proportion of distilled water and acid, if the battery is
either dead or over used

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 Checking the spark of starter plug if it is included and install wires around the starter plug
 Maintain connections of wires of display gauges
 Checking and maintaining the connection of dynamo meter
 Plug lights and fans

1.1.2 Manufacturing Shop


In this shop, there are many manufacturing processes executed using machines like lathe
machine, milling machine, bending machine, electrical cutting machine and welding machine.
Although using metals which have different thickness and dimension, they manufacture doors
and windows for different projects.
Manufacturing shop follows the following procedures during manufacturing of this staff
among these
 Analysing designs
 Extracting the required materials
 Manufacturing process
 Delivering the product to customers

1.1.3 Machines Found in the Work Shop


Different machines are used in this work shop. These include lathe machine, milling machine,
boring, drilling machine and their accessories.
Lathe machine Lathe machines are capable of cutting or grinding symmetrical shapes into
materials such as wood and metal. There are countless practical applications associated with
lathe machines. The definition of a lathe is a machine that shapes objects by rotating them while
a shaping tool such as a chisel is applied to its surface. To avoid injury, care should be taken
while operating lathe machines.
Drilling machine: It comes in many shapes and sizes, from small hand-held power drills to bench
mounted and finally floor-mounted models. They can perform operations other than drilling,
such as counter sinking; counter boring, reaming, and tapping large or small holes.
Shearing machine is one of two things; an industrial machine that cuts metal or a machine that
cuts the wool off sheep. An industrial shearing machine generally presses blades down into metal

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sheets to punch out shapes. These shapes may be the desired end product or they may be the
waste product. While shearing metal sheets is most common, other metallic objects may be
processed in one of these machines. A sheep-shearing machine may be anything from a pair
Bending machine, it is a machine used for the hot or cold bending of parts from flat sheet, bar,
tubular, and rolled stock. All-purpose bending machines are of several types, including three-
and four-roll (rotary) machines, roller machines, and machines with a turning traverse, template,
or arm. Three and four roll machines are used for bending sheet stock into cylindrical and
conical shells and arc-shaped components of small clippers similar to ones found in a barber
shop to a large machine that features an external power supply and multiple clipping arms.

1.1.4 Challenges and Problems I Have Been Facing While Performing Tasks
Like most of workshops in Ethiopia, these shops have its own challenges which drag the shops
work quality and productivity. Among these challenges the following can be considered as the
major ones.

• Adapting the workers and the compound

• Shortage of tools and equipment

• Lack of safety guarded materials


• Improper arrangement of materials in the store  There is no efficient skilled man power.
• Time taking respond of officials to maintain vehicles and for required spare parts

• There was a communication problem with mechanics because they often use Italic jargon
words for naming tools. Some manuals are even prepared in Italic since they are
manufacturer there.

Measures Have Been Taken to Overcome the Challenges


 I tried to approach workers being friendly and after working for a certain time, I started
discussing and helping each other for solving problems and other work relate issues.
 As much as possible, I tried to use the available tools for performing tasks which should
have been done by the recommended ones. But since the shops still lack basic tools like
hydraulic puller which I can’t replace it by using other tools instead, I decided to make our
project on designing one of these tools and solve the problem.

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 I also tried to adapt the working place by taking measurements like communicating with
workers, selecting cloth and shoes which are related to the environment and working
conditions.
 Through time I experienced to tie & lose nuts & bolts and assemble & disassemble of
vehicle parts with the help of skilled and experienced technicians who were willing to share
their skills and knowledge’s.

1.1.5 Work Flow in The Section

The first work is just visual inspection and looking for the problem from the vehicle and also
checking the oil changed date and also reading the check engine code if any problem is facing
the engine. Since the buses are new and uses ECU, it is easy to see the problems from the dash
board.

After understanding the problem, the mechanics check if the parts can be repaired and solved
without any wastage but if the parts must be changed, they request for the purchase and
warehouse and then assemble the new part and test the bus after assembly.

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CHAPTER TWO

2 OVERALL BENEFITS GAINED FROM INTERNSHIP

2.1. Benefit gained from practice skill

Any aspiring Mechanical Engineer should know that the field demands practical skills.
Concerning Practical Skills, being assigned at the motor section was somewhat helpful in
developing this skill. Throughout my stay, we have been assembling and disassembling an
engine and gearbox, and that makes us to gain some practical skill. After this intern ship we
know how to assemble and disassemble.
Assigned in electric section also helpful in developing my practical skill, in electric section also
there is assembling and disassembling an alternator and a starter.

2.2. Benefit gained according to theoretical knowledge skills

The things that we learn in theoretical makes everything easy to understand everything. In this
intern ship we sow the things that we learn in theoretical and it’s increasing our knowledge.
Theoretically we learn about flywheel, gearbox, bearing, piston, crankshaft, camshaft, clutch etc.
… watching the materials in person makes everything easy. For example, we have a deep
knowledge about a flywheel and know how it works, how it can be assembled and how to use it.
And we sow gearbox also, we sow how every gear are assembled and disassemble also know
how it works and we gained so much knowledge.
This intern ship helps me to learn new things that we haven ‘t learned in theoretical or haven ‘t
seen before. For example, the things that we learn are injection pump, oil pump, cooler and etc.
we know how to assemble them and know what is there uses also where to assemble them. In
electric section also, we learn the things that we didn’t learn in theoretical which are starter and
alternator. We know how to assemble and disassemble both and know the uses and function. In
this intern ship we didn’t gain knowledge only the thing we learn in theoretical, we also gain a
new thing that we didn’t learn in theoretical. So, we can say that this intern ship helps us to
know new things and increase the knowledge that we have been learning in the theoretical
lessen.

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2.3. Benefit gained in terms of improving my interpersonal communication skills

When we were enrolled at the company, our first goal was to develop our interpersonal
communication skills. It is obvious that this line of work (Mechanical Engineering) requires such
skill. This would enable us to communicate with people from different walks of life.

In this regard, we had great help from our supervisor. Starting from the first day, he was very
easy to talk to and communicate with. We heard that Supervisors aren’t very welcoming about a
student following them everywhere they go while they work. We were also told they work
racing with time every day so we were very much suspicious about creating a pleasant
communicating environment with our supervisor.

To our surprise, he was more than welcoming. He said we can improve my skills mainly by
focusing on getting familiar with the language used at the section. He highlighted that my
greatest problem would come while communing with the daily workers. The words being used at
the section some of were different from what we know theoretically.

Furthermore, developing a friendly, open personality was also an essential element for a better
understanding between staff members. Our supervisor was a shining example as we closely
followed his daily activities. He treated all those who were lower than him with the same respect
he showed for his boss. We learned even the smallest “hi” in the morning had an effect.

At the end of the day, we are confident to say we have learnt to show respect any employee;
even if it a guard, a daily worker or a Project Manager. Learning some terms and the language a
daily employee uses eased my communication and lifted any communication barriers created
otherwise. we can also safely say we learned to give much emphasis to mutual understanding
with any staff member.

2.4. Benefit gained in terms of improving my team playing skills

When one develops interpersonal communication skills, it is easier to communicate with a team
and develop team playing skills. Understanding peer groups is all part of the communication
process.

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Team play is much more than individual play, because in team play, we can share ideas and if
any one makes mistake, we can correct each other. But in individual no one is perfect so if we
did mistake no one will correct me. Some people went to do individual but we rather do team
play. This thing helps us to develop our team playing skills to some extent. We learn the
different idea comes in many directions. We usually used to do things individual but after
internship we understand working in group ‘s batter than working with individually for gaining
different ideas.

2.5. Benefit gained in terms of improving my leadership skills

If one chooses to actively take part in what goes on the team, he/she will take active role to serve
and benefit the team. This can be considered as a developed Leadership skill. There were also
opportunities in which we developed my leadership skills one of them is when new interns
joined the company, we were assigned to explain every single detail that we know and control
and guide their work when they were given to see and understand everything. we tried to make
everything as clear as possible by giving examples to avoid confusion.

Problems in the company come in different direction, on different period of time. Thus, a person
who is in the position of leadership seeks optimal solution to problems and should be smart
enough to manage those individuals whom he/she is leading. Here in our every place is occupied
with the right person, this person has a responsibility so they do their work effectively.
Therefore, no one gives us a position to experience this thing. But we learn more from them how
they are good on lieder ship and how to coordinate their team members to solve any problem.

2.6. Benefit gained in terms of work ethics looking at Work Ethics Skills

The first and major responsibility of a disciplined employee is to have work ethics. The benefits
of work ethics go as enormous as organizational levels. Developing work ethics helps for the
creation of a smooth working environment between employees.

One quality of an ethical employee is respecting time and coming to work early. we have been
aware to the time schedules of a school system for over fifteen years so getting to work in the
morning and taking a lunch break to come back to work was a bit hard to adapt. However, one

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has to master such skill so that they can carry out tasks and assignments on time and without
interval.

Ethical conduct of workers is very important for developing healthy working environment and
increasing productivity. From this perspective, we‘ve gained a valuable lesson that transparency
and carefulness are two very important work ethics one needs to tolerate and live by. Respecting
the guidelines of an employing company is imperative. This includes mastering the skills of
work ethics. We were never disrespect of Qualities like integrity, commitment and honesty but
we have developed them more at my stay as they are the symbols of a good and efficient
employ.

2.7. Entrepreneurship skills

A wide range of skills are seen as entrepreneurial and useful to entrepreneurs, these include both
personal traits and skills such as: management skills, communication skills and the ability to sell
ideas and persuade others, the ability to work both as part of a team and independently, self-
motivated and disciplined, the ability to multi-task and there are many advantages to develop our
entrepreneurship skill while we are in the intern ship.

To developed our ability in terms of;

 To learn new skills and add to our knowledge base while confidence in our
abilities
 Can apply some of the ideas learning in universities.

 Cultivate adaptabilities and creativity in a dynamic world.

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CHAPTER THREE

3 INTERNSHIP PROJECT

3.1 Title of the project


Our intern ship project title is “design fuel injector tester”

3.2 Introduction
Mechanical unit injector tester machine is manually operated machine which used to ensure
proper functioning of injector by testing it. The operation of this machine is manually control and
for batter to convenience this machine is converted into automatic.

This injector tester machine consists of two side, supply side and delivery side. This side consist
of following components and they are pumping system which is used to pump the fuel in to the
injector, fuel tank which used to store fuel into the injector, battery which used to control the
voltage and the current by ECU system, which means it used by harnesses but in this injector
tester there no ECU because this material is expensive so for this machine we used to common
rail.

Parameters that affect the performance of fuel injector


Flow
The flow rate is important for complete combustion of the fuel because every engine cylinder has
a certain amount of the fuel that can be burnt with maximum efficiency for equivalent of 15
second continuous operation, the rate of flow is critical to the combustion as its usually the
standard time of operation for most manufacturers.

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Leaks
Leak can be through the Tapir internally or usually due to valve unable to fully close which in
both cases cause the leak of fuel from the injector if there is no leak with the fuel injector then
the problem may be in the fuel pump or distributor unable to set the timing.

Spray pattern
If the flow rate is optimized and there is no leak the spray pattern will affect the combustion of
the fuel usually spray pattern is result of change in the fuel injector nozzle projection that change
the shape of the pattern of the spray which result in decrease in the fuel combustion Efficiency

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3.3 Operating principles of fuel iinjector tester stand machine


The working principle of fuel injector tester is quite similar to that of fuel injection system of an
automobile.
 The fuel injector consists of several of part:
 Fuel injector (to inject the rite amount of fuel in the rite spray pattern)
 Fuel pump (to pump fuel from the fuel tank)
 Distributor (to transfer fuel)
 Battery (to provide current)
 Carafes (to determine the amount of fuel injected)
 Electrical motor (to actuate the distributer)

When the current from the battery flow through to the pump it will actuate the pump, then pump
will pump the fuel from the fuel tank and supply it to the fuel gallery at the same time the
electrical motor actuate the distributor that passes current to the fuel injector to actuate the
injector coil and valve that allows the fuel to be injected the amount of fuel that is injected is
collected inside a flasks along with the spray pattern which is seen through the glass of the flask.
The amount of fuel that is collected in the flask is compared with the manufacturer standard
amount of fuel 15second continuous operation; the spray pattern is also compared with the
standard spray pattern provide by the manufacturer of the injector.
Advantage
The fuel injector test has two advantages according to the view of economy and environment.
 From economical point of view
A good fuel injector reduces the amount of unburnt fuel thus saves money. By optimizing the
fuel flow rate and spray pattern the combustion is a complete combustion and no residue is
formed in the cylinder than may cause any damage to the engine cylinder or the exhaust system
thus improve their survivability
 From environmental point of view
A good injector reduces the emission of harmful gases to the atmosphere such as Co,Co2, and
fuel particle that are harmful to humans and all living being .as people became aware of the
environmental problem that surround our world the contribution of every human is important to
the wellbeing of earth.

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Disadvantage
In case of improper implementation of the test in accurate result will be generated that may lead
to improper diagnosis that will be led to costly maintenance in the future and costly time delay.
By logical reasoning, FI being a newer tech should be better, but there are advantages and
disadvantages. The working of the Fuel Injection system is more computerized and works on a
lot of sensors. The fuel injection nozzle is provided directly in the combustion chamber.

3.4 Statement of the problem


This project is done depending on the problem while injector is sprinkled from the fuel filter and
putting the injector to the tester stand.

In the workshop I perform our internship the system that they use to injector tester is single
injector tester, very old and it not effective and wastage of fuel injector. I think this project uses
in order to solve this problem simply or in order to cheek injector simply and safely. This system
allows us to use the injector for many times.
3.5 Problem solution(justification))
To solve this problem, I have proposed that a fuel injector tester or easily test injector in a short
period of time. This machine minimizes time consumption and man power, from three or four
man power in to only one man power. this machine simplifies the problem by:
 Avoid more time
 Highly efficient
 Not tediouss
 Minimise cost
Totally I have justified the problem by introducing a fuel injector tester which having some

3.6 Objective

General objective
 The main objective of the project is to protect the fuel injector.
Specific objective
 To design fuel injector tester.
 To Identify geometrical.

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 To increase working time.


 To reduce the number of workers.
 To design the machine by using locally available and low-cost material.

3.7 Scope
The design and construction of these fuel injector tester and easily, efficiently test fuel injector.

3.8 Significance
The design of fuel injector tester is a device for test fuel injector. It comes with various
advantages, namely the following.

 Can be used by small and medium garages.


 It is suitable for use in a commercial auto repair facility.
 Will greatly improve the efficiency of the worker/technician.
 The garages will have the advantages of working according to international standards.

3.9 Limitation

The limitation we have been facing during project work:

 There is no computer access to develop the project given by the company and to
prepare this project.

 There is no access of materials and tools to manufacture the machine.

 There is no free Wi-Fi access. This creates challenge to get raw data for this project.

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CHAPTER FOUR
4 LITREATURE REVIEW AND METHODOLOY

4.1 LITREATURE REVIEW

The project describes the design and analysis of manually operated injector tester. This machine
is used to know how well the injector is responding for the given fuel. In old method the injector
is tested by using compressor and with hand. Sometimes it may cause loss more time and dose
not effective. In this case may be the injector to used again but does not use long time forth with
stop. Since it needs more than one person and it will make more time consuming and increases
the cost of reconditioning the injector. The workers strained very due to impracticality to check
the injector.
Also, that is not easy to check which one injector fail or damage. That it was not safe as the
worker time and injector life duration. Also, great care should be taken testing machine not to
damage the injector and loss time. Development of more than two persons to do or make the
injector and then to order from engine block is not only the great loss to the auto mobile
workshops but also the wastage of time and increased material cost resulting to increase the
overhead cost of reconditioning the injector. Most of the times it is difficult to replace or service
injector due to the location size, method of coupling, as a result, it is often times necessary to the
engine entirety to replace or repair the injector. In some instances, the entire machine must be
transported to a maintenance facility to replace the injector. However, it is desirable to replace
injector without
 Requiring injector taster assembly
 Increased material cost and time duration
Specifically, as we have seen in Anagaw Getachew Turno house service centre the problem
associated with injector tester and installation is not only those explained above but there is also
lack of some required standard sprinkle injector tester. Where these components are very
essential for the job the technicians order these tools from Anagaw Getachew Turno house and
waits until the arrival of the tool. As we know this consumes an additional time and also
increases overall maintenance cost by additional material cost needed to the tool. Additionally,

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due to the delay of maintenance the company income will be affected. Significant of the activity
in addressing the problem stated.
Due to above listed problems we decided to design the technology of injector tester and installer
machine. This machine is simple, easy, and safe, take short period time to operate and reduce
man power,

4.2 METHODOLOGY

The project refers to planning and overseeing the tasks necessary to achieve a goal. It is
important because it insures proper expectation is set around what can be delivered. It also helps
to have better control of the variables which contribute to the well-being of the project process.
For these reasons I tried to follow some procedures which will enable the whole project to be
efficient and effective.

Introductio Literature Design concept


n and Design concept Evolution
review
Generation
Backgroun

Result and Product


Design all Material
Discussion Definition
components selection

Pare drawing Assembly


drawing

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4.3 DESIGN OF INJECTOR TESTER


All parts of the machine are designed carefully in step-by-step form. The machine has mainly
parts.
1. Power screw
2. Nut design
3. Plate
4. Stand
5. Injector hole
6. Connector hole

Design of power screw

I need four Screws and it is the main part of the first stand that experience a tensile and torsional
shear stress due to the load applied.

Identification of a problem

Each nut carries half the total load of the stand.

Mass of the housing is neglected

The starting and running frictions remain the same.

Assume the maximum load applied to the injector is 6KN.

Required
 Diameter of the screw
 Outer diameter
 Core diameter
 Mean diameter
 The effort required to rotate the screw
 Torque required to rotate the screw

In this design I select the square thread (normal series) screw because of:-

 The square thread results in maximum efficiency.

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 It has minimum radial pressure on the nut.


 It is difficult to cut with taps and dies, but cut by using lathe machine.
 It cannot be easily compensated by wear.

Material selection

Material with less cost but sufficient strength is selected.

Properties of materials to consider before selecting the design proses

 Strength and Rigidity


 Cost and Availability
 Durability and Reliability

By considering the above points I select steel alloy ASTM (class a60) for this screw design and it
have these mechanical properties;

 Tensile strength (σ t) =431Mpa


 Compressive strength (σc) =1293Mpa
 Shear stress (τt) =610Mpa

Talking factor of safety of 2 due to the nature of the application, then allowable tensile stress and
shear stress will be

σall =σt/F. S

= 431Mpa/2

=215.5Mpa Ans

τall=τt/F. S

=610Mpa/2

=305Mpa Ans

Analysis

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A little consideration will show that if one complete turn of a screw thread be imagined to be
unwound, from the body of the screw and developed, it will form an inclined plane as shown.

And by considering that the maximum load on the square threaded screw occurrs when the
frame of an engine block is at the bottom position so I take ϴ is 20°. Then the equation will
come:

Fpull=W/2tanϴ................................................................................................................ [1]

=6000N/2tan20

=8253.094N

Let dc is the core diameter of the screw, we know that the load acts on the screw (FPULL)

F pull=AC×σt.................................................................................................................... [2]

Where AC is the cross-sectional area of the screw

π
AC= 4 (dc)2............................................................................................................................[3]

And we have the allowable tensile strength

σall=215.5Mpa

π
F pull= 4 (dc)2×σall............................................................................................................[4]

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4∗FPULL
dc=√ π∗σall ......................................................................................................................[5]

4∗8253.094
=√
π∗215.5

=22.68…......................................................................................................................... (Soln,)

 The screw is also subjected to torsional shear stress therefore to account for we
approximate to the nearest standard value of core diameter.
dc=23.5mm
by using his value, the pitch is taken as;
p=6mm
Outer diameter will be (do)
do=dc+p.........................................................................................................[6]
=23.5+6
=29.5mm≈ 30 mm….................................................................................. (Soln.)
And the mean diameter of the screw (dm)
P
Dm = do- 2 ...............................................................................................[7]
6
=30-
2
=27mm
Let us check the principal stress. We know that
p
Tanα = π dm ................................................................................................... [8]
6
=
π × 27
=0.0707
And we know that effort required to rotate the power screw
P=F׿)................................................................ [9]

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Where, tanα is coefficient of friction between the screw and nut for poor workman
ship or very slow and in frequent motion with indifferent lubrication or newly machined
surface
Use μ = tanϕ
= 0.21 from the standard books.
0.0707 × 0.21
p =8253.094× ( )
1−0.0707 × 0.21
=123.142N……………………………………………………Ans

Torque required to rotate the screw is

dm
T=P× 2 ............................................................................................. [10]
27
=123.142×
2
=1662. 417Nmm.....................................................................................Ans

And shear stress in the screw due to torque

16 T
τ= π ×(dc )2 ................................................................................................[11]

16 ×1662.417
=
π ×(23.5)2

=15. 471Mpa.................................................................................................Ans

Direct tensile stress in the screw is

Fpull π
σt = …………………. where, AC= 4 (dc)2....................................................[12]
AC

4 × FPULL
σt= ¿ ¿
π ×(dc )2

4 × 8253.672
= =19.0291Mpa............................................................................................[13]
π × ( 23.5 ) 2

Then we check the following Maximum stresses;

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Maximum tensile stress theory

σt 1
σt(max)= + √ σt2+4 τ2
2 2

19.029 1
= + √19.9462+4×15.4712
2 2

=127.67Mpa

 σall≥ σt(max)
215.5≥ 127.67 ……………....................................................…………...SAFE

Maximum shear stress theory

1
τmax= √ σt2+4 τ2
2

1
= √ 19.02912+4×15.4712
2

=67.364Mpa

τall≥ τ max

305Mpa≥ 97.364 Mpa …………………........................…………………. SAFE

Distortion theory

σd =√ σt2+3τ2

=√19.02912+3×15.4712

=123.663Mpa

 σall≥ σD
215.5 Mpa ≥ 123.663 Mpa ……………………………….……....................SAFE

Checking for self-locking

μ≥ tanα ………. Where, μ=0.21

tanα=0.0707…………0.21¿0.0707………………. So, it is a self-locking screw.

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Efficiency of self-locking screw

We know that the efficiency of screw

tanα
Efficiency (η)= Where, ϕ=tan-1(μ)=tan-1(0.21)
tan ⁡¿ ¿

Φ=11.86

α=tan-10.036

=2.062

0.036
η=
tan ⁡(2.206+11.86)

=0.244≈ 24.4 %

Efficiency of self-locking screw is less than half or 50 % .if the efficiency is more than 50%
then the screw is to be over hauling.

Design of Nut

In this design we have two nuts with different shape and different application but the width, the
thickness, the height, and number of threads for both nuts are the same.

Let n= number of threads in contact with the screwed spindle

w= width of the nut

t=thickness of the nut (n×p)

h=height of the nut

Assumption

 The overall dimensions are given by considering the size of the extractor & the size of the
engine block.
 Assume that the load F is distributed uniformly over the cross-sectional area of the nut.

Material selection

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 The material that we select to design the nut is bronze.


 with yield strength (σy) = 116.7Mpa
 tensile strength (σt) = 350Mpa
 shear stress (τ) = 74.5Mpa

The reason is: -

 To reduces friction and wear for surface in sliding contact.


 Good corrosion resistance.
 High elasticity.
 The cost is relatively medium

Taking a factor of safety two (2) for this design of nut

 The bearing pressure between the threads (pb) is

Where: F is the load on the screw (8253.094N)

Pb is the bearing pressure taking 28N/mm

Do is the outer diameter (30mm)

Dc is the core diameter (23.5mm)

F
Pb= ( Do 2−Dc 2 ) n .................................................................................. [1]
π
4

8253.094 N
28 = π
( 900−552.25 ) n
4

n=13 …………………...….………. (*)

 The thickness of the nut (t) will be


tn=n×p
=13×6
=74mm………………………..............………… (*)

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 The width of the nut (w) is taken as


W=1.5Dc
=1.5×23.5
=36mm ……………………………….......................................................... (*)

Also the height of the nut will be considered the product of pitch and number of thread plus some
clearance between the crew and the nut.

H= p×n+some clearance

=6×13+2

=77mm ………………………………………............................................... (*)

Check the stress in the screw and nut as follows:

Shear stress in the nut

F p 6
Τ nut= where: t is thickness of teeth……. t= = =3mm
π × n× Do× t 2 2

8253.094
=
π ×13 × 30× 3

=2.494Mpa

Shear stress in the screw

F
Τ screw= ........................................................................................................... [2]
π × n× Dc ×t

8253.094
=
π ×13 × 23.5× 3

=2.866Mpa

Since these stresses are with in permissible limit, therefore design for nut is safe.

τnut≪τyield (bronze =74.5Mpa………………………... .............................................Safe)

τscrew≪τyield (steel =305Mpa…………………………............................................. Safe)

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So, the overall dimension of the power screw will be

Length of the power screw=2×length of the liner+ some clearance between the housing and the
liner; when the liner is fully extracted +the product of pitch and number of teeth of the nut

We know that the length of the cylinder is 36cm

=2x360+40+13x6

=838

Design of plate

Plate is one part of the stand. It if used to get mechanical advantage roughly speaking it is a rigid
rod moving about some fixed point or axis.

This plate is mounted to upper the bottom of the stand and also to inter the stand with less effort
to facilitate the application of force in a designed direction.

Assumption

 There is a limitation of application of force on the plate exerted to and inter someone
 Assume that 200N is applied by a person in each handle=400N.

Material selection
 We select a gray cast iron AISI 1040 for this design of plate
 This material special character, better thermal conductor
 Higher level of vibration damping
 Damping capacity that is 20-25 time higher than steel
 Tensile strength ultimate – 700mpa
 Tensile strength yield – 420
 Shear stress –400

Take factor of safety 2.


Then the allowable shear stress and yield strength will be
σy 420
σall= = = 210Mpa
F .S 2

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τ 400
τall= = = 200Mpa
F .S 2
Analysis
First to find the angel between injector and connector
Injector length =8.2
Connector length = 5cm

By Pythagorean theorem
a2 = √ c 2−b 2................................................................................................... [1]
a2=√ 82−42
a2= 6.93
ϴ = tan-1 (opp/adj)
ϴ = tan-1(6.93/4)
ϴ = tan-1(1.732)
ϴ = 600
Or
cosϴ = opp/hyp
ϴ = cos-1(4/5)
ϴ = 600
Design of the bottom plate

The following measurements are what we used but should be confirmed. The best was to make a
bottom plate, or have it made at a machine shop by using the actual new plate for measurements.
The most important is the area of plate they have two plate must be as close as possible to the
injector tester stand it is fit to each other.

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Plate 1
Plates are 15 cm thick
Plate hole 12
Injector hole 6
Connector hole 6
Diameters injector hole 4cm
Diameters connector hole 2cm

Total area
AT = L*W.................................................................................................................. [1]
L = 100cm

W = 15cm

AT = 100*15

AT = 1500cm..................................................................................Ans

But the next area is less than the total area because the there are 14 hole, on the plate

Hole 1 injector placement hole

Aj =2 π r 2............... [2]∅=4 cm r = 2cm N=6

= 2(π*22) N = number of injector hole

= 25.13cm2.....................................................................................................................Ans

Total injector hole is 6

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A = Aj*6.................................................................................................................. [3]

= 25.13cm*6

= 150,78cm2.........................................................................................................Ans

Hole 2 connector placement hole

AC = 2πr2............... [4]∅=2cm r = 1cm N=6

= 2(π*12) N = number of connector hole


= 6. 283cm2................................................................................................................Ans
Total connector hole is 6
A = AC*6............................................................................................................. [5]
= 6.283*6
= 37.698cm2.........................................................................................................Ans
Hole – 3 the hole for bolt

AB = 2 πr 2∅=2cm r = 1cm N =2
AB = 2π*12N= number of bolt hole
AB = 6.283cm2
The net area of the plate – 1

A1= AT – (Aj+AC+AB)
A1= 1500cm2 – (150.78cm2 + 37.698cm2 + 12.566cm2)
A1= 1298.96cm2
Change in meter
1m = 100cm
1m2 = 102cm2
1cm = 10-4m2
A1 = 1298.96*10-4m2
A1 = 0.1298.96m2

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The second plate


The second plate must use an exact sized bottom plate. It must be stepped so that top of the plate
fits inside the stand with no play. The lower section plate must be than the outer the same size
but they have different area and in second plate only six nozzle holes; the step must be machined
precisely to give an even the first plate.
Assumptions
 The maximum load stand has 30KN.
 There are four shafts (support) between the top and bottom annular rings which can
support the maximum load exerted equally on them which mean they will divide it. So,
from them one of shaft support F1=FR/number of supporter → F1=30KN/3 =10KN
 The top and bottom of housing is annular rings.
 The shaft (support) that supports the top and bottom plate rectangular support

Plate – 2

Total area

AT = L*W.............................................................................................. [1]

= 100cm*15cm
= 1500cm2.................................................................................... (ANS)
Hole – 1
∅=2cm r = 2cm N = 6, number of injector nozzle
AN = 2πr2............................................................................................................... [2]
AN = 2(π*12)
=6.283cm2................................................................................................... (ANS)
The total area of the nozzle hole
A= AN*number of injector nozzle............................................................................................ [3]
A = 6.283cm2*6
A = 37.698cm2...................................................................................................................... (ANS)
Hole 2

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∅ = 2cm
N = 2 (the number of bolt)
AB = 2 π r 2 ..................................................................................................................... [4]
AB = 2 π (1 )2

AB = 6.283cm2........................................................................................................ (ANS)

Then multiplied by the number bolt hole


AB = the area of hole two* the number of bolts.......................................................................... [5]
= 6.283*2
= 12.566cm2.......................................................................................................................... (ANS)
After that to be find the net area of plate 2

A2 = AT-(AN+AB) ............................................................................................. [6]


A2 = 1500cm2-(37.698+12.566)
A2 = 1449.73cm2
Or
A2 = 0.1449m2
Design of stand
To find the total stand area
AT = L*W L= 100cm
= 100cm*70cm W = 70cm
= 7000cm2
The net area of the stand
AS = AT-(AP1+AP2)
= 7000-(1500+1500)
= 4000cm2
When in the stand put battery and pump because they are so many important for fuel injector. A
fuel injector with test by battery, first remove the fuel injector from the engine. Next, connect the
positive terminal of the battery to the positive terminal of the fuel injector. Finally, connect the
negative terminal of the fuel injector. If the injector is working properly.

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How to test the fuel injector with battery in this project


1 you will need to remove the fuel injectors from the engine block
2 Then place it to the injector tester stand properly
3 And lock it with the nuts
4 Then place the connector on its place which connects the high-pressure line with the
injector
5 Connect the harness with the injector and the battery
6 Once the battery is connected, you will need to turn the key on to activate the injector
nozzles.
7 After the fuel pump is activated, you will need to quickly tap the battery to simulate the
electrical impulse that goes into the fuel injector
8 You should then see a nice atomization or vaporization of fuel coming from the injector
9 If the spray pattern is not correct or if you see baking that shows the failure of the injector

The purpose of pump in the project is to push the fuel from the reservoir to the injector
And the fuel pump is to create adequate pressure, so that the injector with also deriver the correct
amount of fuel, no matter what the operating condition.
For the vehicle they are standard length and weight for battery and fuel pump
The length of battery = 9-10inch
The width of battery = 5-7inch
The high of battery = 8-9inch
Then, the purpose of pump in this project draws the fuel from the tank through fuel lines and
delivers it through a fuel filter to either a carburettor or fuel injector and finally to the cylinder
chamber for combustion.
The standard size of pump
Length of pump = 133,5mm
Diameter [1] of pump = 8mm
Diameter [2] of pump = 8mm
Current strength = 2A (number of connectors 2)
Material selection
Material with less cost but sufficient strength is selected.

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Properties of materials to consider;


 Strength and Rigidity
 Cost and Availability
 Durability and Reliability

By considering the above proses grey cast iron ASTM (class a60) for this screw design and it
have these mechanical properties.

 Yield strength (σ sy) =420 Mpa


 Elastic modules =200x109

By using allowable tensile stress and the maximum load exerted on the stand which is720KN

Cost Analysis
Cost analysis is one of the basic needs for any material in order to design the material in a
Minimum amount of cost because of cost minimization is one of the basic goals of any
Engineering methods and also it helps to distribute the goods to the customer in easily due to
This. The manufacture and material cost for this machine are estimated as below.

NO Part Quantity Cost Total Cost Material


1 Power screw 1 700 700 Steel alloy
2 nut 2 500 1000 Bronze
3 Upper pate 1 2000 2000 Cast iron
4 Bottom plate 1 1800 1800 Cast iron
5 battery 1 5000 5000 ________
6 Fuel pump 1 4500 450 _________

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CHAPTER FIVE
RESULT AND DISCUTION
power screw
maximum load applied to the injector is 6KN
core diameter.
dc=23.5mm
Outer diameter will be (do) =29.5mm≈ 30 mm
mean diameter of the screw (dm) =27mm

Torque required to rotate the screw is=1662.417Nmm

Nut

n= number of threads in contact with the screwed spindle =13

w= width of the nut =36mm

t=thickness of the nut (n×p) =74mm

h=height of the nut =77mm

Plate 1
Plates are 15 cm thick
Plate hole 12

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Injector hole 6
Connector hole 6
Diameters injector hole 4cm
Diameters connector hole 2cm
Total area= 1500cm square

Hole 1 injector placement hole = 25.13cm2

Total injector hole is 6 = 150,78cm2

Hole 2 connector placement hole = 6.283cm2

Total connector hole is 6 = 37.698cm2

Hole – 3 the hole for bolt AB = 6.283cm2

The net area of the plate – 1 A1= 1298.96cm2

The second plate

Total area = 1500cm2

Hole – 1 =6.283cm2

The total area of the nozzle hole = 37.698cm2

Hole 2 = 6.283cm2

net area of the stand = 4000cm2

battery

The length of battery = 9-10inch


The width of battery = 5-7inch
The high of battery = 8-9inch

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fuel pump

The standard size of pump


Length of pump = 133,5mm
Diameter [1] of pump = 8mm
Diameter [2] of pump = 8mm
Current strength = 2A (number of connectors 2)

FRONT VIEW

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SIDEVIEW

switch

battery
Common rail

Fuel pump
TOP VIEW

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FULL

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ASSEMBLY

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CHAPTER SIX

5 CONCLUSION AND RECOMMENDATION

5.1. Conclusion

The internship period plays a great role to relate student’s theoretical knowledge with
practical skill. This helped us to know my strengths and areas for improvement by
overshooting the future career with respect to my field of study. Also, I know the
application of mechanical machines which are found in industrial environments better
than before.
Generally During our internship period: -
➢I have able to understand that most of mechanical machine maintenance
 I have seen maintenance of engine.
➢I have seen the assembling and maintenance shops
➢I have seen practically how-to assembly and disassembly of heavy-duty trucks
➢I have practically checked our knowledge of maintenance and testing section
➢I have seen how electromechanical system and sensors have been used in automation.
➢Generally, I have seen a lot of practical works that I have learned theoretically.

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DEBRE BERHAN UNIVERSITY INTERNSHIP REPORT 2015E.C

5.3 RECOMMENDETION

During the intern ship period we have got a chance to observe so many interesting knowledge ‘s
that can help us for outside of school life. From those some of them need to be improved, some
are listed below.

 For our hosting company

The main problem is availability of spare parts in the store room. Some parts will not be bought
on time. This makes delay on finishing time. Parts in the store room will not be stored properly
they may not be found when they needed and they may be damaged from improper storage. Like
bearings, bolts, valves etc.
We observe that the removing of some parts is not safe it takes much more time so if the
company uses our machine, it can solve these types of problem.

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DEBRE BERHAN UNIVERSITY INTERNSHIP REPORT 2015E.C

REFERENCE
1.Textbook of machine design, R.S Khurmi, 2010
2.Strength of material, 4th edition, William A. Shash, McGraw-Hill.
3.Shingles Mechanical Engineering Design, Eighth Edition, Budynas−Nisbett, McGraw-Hill.
4 https://www.howacarworks.com/basics/how-a-fuel-injection-system-works.

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