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Open Issues in Theta GDI Production Design and Testing Updates

The 2009 MKL Engineering Presentation addresses crucial open issues in the Theta GDI production design. Key updates include finalized BSM design, pending changes to Spring and housing designs, and the completion deadline for 2D component drawings. The importance of EOL specifications for GDI modules and ongoing investigations into cavitation and oil pump noise issues are highlighted. Additionally, there are concerns regarding M6 bolt assemblies and proposed material changes for oil strainers aimed at cost reduction. Relevant action items and testing progress are also discussed.

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Open Issues in Theta GDI Production Design and Testing Updates

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Presentation Transcript

  1. MKL EngineeringPresentation2009. 9. 21.

  2. Theta GDI Open Issues • Production design - There has been design changes for each customer event. - BSM design for PP stage has been finalized. - Spring and housing 3 designs may be changed near soon. - 2D component drawings should be completed by Sep 23rd(KST) as they are. • EOL spec for GDI module - ESP limit is required for the production and EOL correlation. - MKL needs to have EOL spec even though the interim limits for the customer audit scheduled on Sep 24th. • DVP&R - MD to perform the DVP&R for PP design. - Plymouth is processing high speed and sweep test currently.

  3. Theta GDI Open Issues • Cavitation issue - Severe cavitation mark found for GDI P2 module tested 320hr high speed in HMC. Actually rated speed increased from 6000erpm to 6300erpm and oil pump performance was changed from current MPI version. - Plymouth is investigating the BSM in detail.

  4. R-BSM Open Issues • Oil pump noise issue - Current production module shows the border line for oil pump noise. - HMC and MKL is trying to improve the NVH through the axial clearance. This may help MD to eliminate induction hardening for driven shaft. • M6 bolt issue - MKL had M6 bolt assembly trouble with the breakage and the elongation at the bolt thread recently. - Plymouth will do the bolt clamping capability review with the housings and bolts provided by MKL. And also MKL is doing the trial with no machined mounting surface of housing 1 in order to increase the friction coefficiency. • Oil strainer material change - The change of oil strainer material was suggested due to cost reduction. - HMC completed engine feasibility test for the changed material and asked to submit CFR print by Sep 25th.

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