The purpose of this study is to increase the accuracy and durability of the fuel level sensor that detects the amount of fuel inside the automotive fuel tank; and to optimize the quality of metallic material of contact, conductive ink(in other words, conductive paste or conductive track) which are t...
The purpose of this study is to increase the accuracy and durability of the fuel level sensor that detects the amount of fuel inside the automotive fuel tank; and to optimize the quality of metallic material of contact, conductive ink(in other words, conductive paste or conductive track) which are the main components of the fuel level sensor, for the purpose stated above.
The qualities of automotive fuels of various countries world wide are different; the corrosion resistance and chemical resistance should be proper for various fuels such as the fuel containing alcohol, bio-diesel, as well as the sulfur and water contained in fuels; moreover, customers(vehicles manufacturers) are requiring the fuel level sensor(fuel level gage) which has the durability of more than 10 years. To meet the requirements stated above, the wears of the sliding contact of the wiper contact and conductive ink should be minimized, and the electrical signal noise of level sensor due to the wear and corrosion should not occur.
For the optimization of materials, it is required to comprehend the requirements and expectations of customers(automobile and automotive components manufacturers) to select and test the various materials, and it is also needed to clarify and implement the robust design at the design and development phase.
The purpose of this study was to design that meets the quality level of the Six Sigma Performance(3.4 Defects per million opportunities, 3.4 DPMO) through the effective experiment utilizing the DFSS Methodology
(IDDOV Process) that is preferred by automobile manufacturers.
Every experiment for every occasion should be conducted for the Full Factorial Design, and the method has the inefficiency of the exponential increase of the number of experiments due to the increase of levels and factors. Thus, Dr. Taguchi's Robust Design Method that made use of the minitab software was utilized at the experiment and verification stage, and the best material condition was found out through the S/N ratio chart, to overcome the inefficiency mentioned above.
At the parameter diagram for the optimized design of materials of the fuel level sensor, the control factor are the contact shape, the contact force and the conductive ink material, the post-process conducted after conductive ink firing. And, the noise factor is the fuel temperature and the fuel type. Also, the input of the fuel level sensor is the Voltage, and the output is the signal noise and the wear rate.
When considering the levels of the above each control factor for the experiment on verification of the development process, the Pd100, Au100, and AuPd10 were selected for the materials of contacts at the experiment level ; 6g, 10g, 16g, 20g, 24g were selected for the contact force,
AgPd55, AgPdAu(45:35:20), AuPtPd(76:15:9, trademark C6011) were selected for the conductive ink materials on the resistor card ; the chamfer 30 and the Radius 3,0 were selected for the shape of the contacts; in addition, the only Brushing process, Erasing & Brushing process, N/A(Not Applicable) were selected for the post-process after the conductive ink firing at the experiment level.
The combination of the various factors selected above from group#1 to group#3 for conducting the experiments, based on the technology, references and experiences of the companies developing and mass-producing the fuel level sensors was considered; and the direction of the experiment on verification was set through the discussion with engineers and considering the technical specification of customers(automobile manufacturers).
To summarize the results of the experiment, when only considering the wear rate of the contact material, the Au100 contact showed the less wear rate compared to that of the AuPd10 contact; also when observing the wear rate of the counter conductive track which is assembled with the fuel level sensor, the counter conductive track that assembled the Au100 contact showed the less wear rate compared to that of AuPd10 contact assembled.
However, it was verified that the hardness of Au100 is very low, and the debris occurred due to the traces of wear around the contact, which is because of the features of Gold100% material, so that there was a quality risk to perform the role of the contact.
To summarize the results of the contact force and the contact shape; the low contact force triggered the less wear rate of the contact and the conductive track on resistor card; however, the signal noise was occurred from the fuel level sensor below which is below 10g; when the contact showed the unstable contact with conductive track on resistor card due to the low contact force, the signal noise was occurred due to the small contact area. In the case of the contact shape(=configuration), the contact which has the Radius 3.0 showed a slightly better characteristics compared to that of the contact having the Chamfer30; however, it was hard to say the difference.
To summarize the results of the conductive track material, the AuPtPd(76:15:9, C6011) conductive track showed the less wear rate compared to that of the conductive track with other materials. However, the problem of increasing the wear of the counter contacts combined with the AuPtPd(76:15:9, C6011) conductive track material.
The AgPdAu(45:35:20) conductive track material showed the less wear rate compared to that of the AgPd55 conductive track material, and showed the positive effect which minimized the wear of the combined counter contacts.
To summarize the results of the post-process conducted after the conductive track firing of resistor card; the conductive track surface with Erasing & Brushing Process became most smooth, and showed the less wear rate.
This study intended to minimize the wear of the conductive track on resistor card and the contacts of the fuel level sensor for automobile; and also aimed to realize the fuel level sensor which meets the quality and engineering requirements or expectations from customers at the design and development phase, utilizing the DFSS(Design For Six Sigma), when selecting the optimized material which does not occur the Signal Noise; in addition, the study drew a conclusion that the best condition of the wiper contact and conductive track on resitor card is as follows, through the effective number of experiments utilizing the Dr. Taguchi's Orthogonal Array table and the optimized phase of S/N ratio and β(the direction of reducing the distribution).
The contact of the AuPd10(Au90 wt%, & Pd wt10% Alloy, Ref. Hv 83)
should be applied for the fuel level sensor for automobile; and the
contact force should be designed as relatively low (about 16g is the
optimized value),
however, the overly low contact force(below 10g) can occur the Signal
Noise.
For the conductive track material of resistor card, the AgPdAu(45:35:20, Ag45 wt%, Pd35 wt% and Au20 wt%, Ref. Hv 100) should be applied; and when Erasing & Brushing is applied for the post-process after the firing of resistor card, the wear of wiper contact and conductive track on resistor card can be minimized, also, the occurrence of the Signal Noise can be prevented.
The purpose of this study is to increase the accuracy and durability of the fuel level sensor that detects the amount of fuel inside the automotive fuel tank; and to optimize the quality of metallic material of contact, conductive ink(in other words, conductive paste or conductive track) which are the main components of the fuel level sensor, for the purpose stated above.
The qualities of automotive fuels of various countries world wide are different; the corrosion resistance and chemical resistance should be proper for various fuels such as the fuel containing alcohol, bio-diesel, as well as the sulfur and water contained in fuels; moreover, customers(vehicles manufacturers) are requiring the fuel level sensor(fuel level gage) which has the durability of more than 10 years. To meet the requirements stated above, the wears of the sliding contact of the wiper contact and conductive ink should be minimized, and the electrical signal noise of level sensor due to the wear and corrosion should not occur.
For the optimization of materials, it is required to comprehend the requirements and expectations of customers(automobile and automotive components manufacturers) to select and test the various materials, and it is also needed to clarify and implement the robust design at the design and development phase.
The purpose of this study was to design that meets the quality level of the Six Sigma Performance(3.4 Defects per million opportunities, 3.4 DPMO) through the effective experiment utilizing the DFSS Methodology
(IDDOV Process) that is preferred by automobile manufacturers.
Every experiment for every occasion should be conducted for the Full Factorial Design, and the method has the inefficiency of the exponential increase of the number of experiments due to the increase of levels and factors. Thus, Dr. Taguchi's Robust Design Method that made use of the minitab software was utilized at the experiment and verification stage, and the best material condition was found out through the S/N ratio chart, to overcome the inefficiency mentioned above.
At the parameter diagram for the optimized design of materials of the fuel level sensor, the control factor are the contact shape, the contact force and the conductive ink material, the post-process conducted after conductive ink firing. And, the noise factor is the fuel temperature and the fuel type. Also, the input of the fuel level sensor is the Voltage, and the output is the signal noise and the wear rate.
When considering the levels of the above each control factor for the experiment on verification of the development process, the Pd100, Au100, and AuPd10 were selected for the materials of contacts at the experiment level ; 6g, 10g, 16g, 20g, 24g were selected for the contact force,
AgPd55, AgPdAu(45:35:20), AuPtPd(76:15:9, trademark C6011) were selected for the conductive ink materials on the resistor card ; the chamfer 30 and the Radius 3,0 were selected for the shape of the contacts; in addition, the only Brushing process, Erasing & Brushing process, N/A(Not Applicable) were selected for the post-process after the conductive ink firing at the experiment level.
The combination of the various factors selected above from group#1 to group#3 for conducting the experiments, based on the technology, references and experiences of the companies developing and mass-producing the fuel level sensors was considered; and the direction of the experiment on verification was set through the discussion with engineers and considering the technical specification of customers(automobile manufacturers).
To summarize the results of the experiment, when only considering the wear rate of the contact material, the Au100 contact showed the less wear rate compared to that of the AuPd10 contact; also when observing the wear rate of the counter conductive track which is assembled with the fuel level sensor, the counter conductive track that assembled the Au100 contact showed the less wear rate compared to that of AuPd10 contact assembled.
However, it was verified that the hardness of Au100 is very low, and the debris occurred due to the traces of wear around the contact, which is because of the features of Gold100% material, so that there was a quality risk to perform the role of the contact.
To summarize the results of the contact force and the contact shape; the low contact force triggered the less wear rate of the contact and the conductive track on resistor card; however, the signal noise was occurred from the fuel level sensor below which is below 10g; when the contact showed the unstable contact with conductive track on resistor card due to the low contact force, the signal noise was occurred due to the small contact area. In the case of the contact shape(=configuration), the contact which has the Radius 3.0 showed a slightly better characteristics compared to that of the contact having the Chamfer30; however, it was hard to say the difference.
To summarize the results of the conductive track material, the AuPtPd(76:15:9, C6011) conductive track showed the less wear rate compared to that of the conductive track with other materials. However, the problem of increasing the wear of the counter contacts combined with the AuPtPd(76:15:9, C6011) conductive track material.
The AgPdAu(45:35:20) conductive track material showed the less wear rate compared to that of the AgPd55 conductive track material, and showed the positive effect which minimized the wear of the combined counter contacts.
To summarize the results of the post-process conducted after the conductive track firing of resistor card; the conductive track surface with Erasing & Brushing Process became most smooth, and showed the less wear rate.
This study intended to minimize the wear of the conductive track on resistor card and the contacts of the fuel level sensor for automobile; and also aimed to realize the fuel level sensor which meets the quality and engineering requirements or expectations from customers at the design and development phase, utilizing the DFSS(Design For Six Sigma), when selecting the optimized material which does not occur the Signal Noise; in addition, the study drew a conclusion that the best condition of the wiper contact and conductive track on resitor card is as follows, through the effective number of experiments utilizing the Dr. Taguchi's Orthogonal Array table and the optimized phase of S/N ratio and β(the direction of reducing the distribution).
The contact of the AuPd10(Au90 wt%, & Pd wt10% Alloy, Ref. Hv 83)
should be applied for the fuel level sensor for automobile; and the
contact force should be designed as relatively low (about 16g is the
optimized value),
however, the overly low contact force(below 10g) can occur the Signal
Noise.
For the conductive track material of resistor card, the AgPdAu(45:35:20, Ag45 wt%, Pd35 wt% and Au20 wt%, Ref. Hv 100) should be applied; and when Erasing & Brushing is applied for the post-process after the firing of resistor card, the wear of wiper contact and conductive track on resistor card can be minimized, also, the occurrence of the Signal Noise can be prevented.
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