Manas Phatak

Title - Modeling and Simulation of Low Pressure Fuel Injection System
Background
Fuel Injection System is a huge development in automotive engineering since it has to be able to deliver the benefits of making your vehicle less polluting and more fuel efficient. The fuel injection system is designed for lifetime, i.e. the components will not be changed. Today simulation models are an integral part of any development process concerning hydraulic machines. An improved methodology for developing these simulation models will affect both the development cost and time in a positive manner. Traditionally, specific simulation models dedicated to a certain pump or motor are created.

Details:
1. Modelisation
The model (low pressure fuel injection system) was developed using 1-D software i.e. AMESim. Various calculations and assumptions were made to modelise the components such as, pump, check valve, filters, pipe, etc. Also during this phase it was required to think of new components that might suite the given specifications.

2. Product Development
This project required to model components which might suite the specifications. One such component referred as "Flow regulator valve" was developed. This component operated based on the hydraulic pressure and no electric component was required. The process of filing a Patent for this product is in process.

3. Experiments on prototypes
Certain experiments were performed in the in-house laboratory on the test bench to validate the idea that was developed during the Product development phase.

4. Simulation
Simulation of the "flow regulator valve" and the entire system is done to validate the idea. Simulation is done using AMESim software and co-simulation is done using Simulink. The main idea to use the solvers of the both softwares was that, as the complexity of the system will increase, without Simulink the simulation time will increase. With Simulink, it is easier to implement the control strategies.

Aim:
The aim of this session was to learn about aircraft engines at the maintenance facility of Air India and to assist the engineers in the maintenance work.

Details:
The purpose was to gain knowledge. The training was carried out in the Engine Overhaul Department of Air India Limited. This department is responsible for the maintenance of different aircraft engines. I had opportunity to study GE and GEnx engines and APU.
During the training period, the basic principle of propulsion was studied followed by detailed study of each engines aircraft maintenance manual.
The engineers were assisted to carryout the maintenance work. This helped in clearing the concepts.

Details:
During the brief spell of work at this company, the first 3 months involved training period where, basic working of the crane, different types of hydraulic circuits were studied. Apart from studying, this period also involved working under the supervision of an experienced engineer.

Responsibilities:
1. Study the Hydraulic Circuit of different types of cranes.
2. Troubleshooting the fault in the crane by analyzing the circuit.
3. Direct the maintenance team to carry out the necessary actions.

Background:
As a part of curriculum, a short project work (8hrs per week for 6 months) was carried out at the Bharat Gears Ltd. This organisation is the leading manufacturer of the gears in India. This project (Performing Gear deburring and hobbing processes simultaneouly) was initiated as the company wanted to save time in the manufacturing line.

Details:
A fixture was designed in order to carry out the deburring of gear during the hobbing process. Generally after finishing the hobbing process (also known as gear shaving process), deburring process was done to remove the burr. This was a little time consuming as the operator needed to unmount the gear from the hobbing machine and mount it on the deburring machine. A small fixture was designed to carry out the deburring process during the hobbing process. Thus there was no need to carryout separate deburring process and hence it saved time in the manufacturing line.