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HMC Theta BS/OPM Weekly Progress Report

HMC Theta BS/OPM Weekly Progress Report. Friday, 23rd July 2004. Introduction.

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HMC Theta BS/OPM Weekly Progress Report

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  1. HMC Theta BS/OPMWeekly Progress Report Friday, 23rd July 2004

  2. Introduction This report contains an activity list that is being used to track Engineering activities associated with the HMC BSM gear whine investigation and other general noise improvement actions. It is updated on a daily basis. Open items on the list are included with status comments. Items that are completed remain on the list for 1 day and are then removed, allowing room for new items to be added as required. The content on each slide is associated with the action item list by the item number in the upper left header. Where conclusions are available, we have included them in this report.

  3. Activity List

  4. Activity List (Continued)

  5. Item 5 – 4 Modules With Ground Gears • 4 “ground” transfer gear sets assembled into HMC BSM at Fremont. • PCW, PDG, PDL, PDJ • Modules tested on EOL test stand. • Modules tested on Roush engine for whine. • Modules PDL & PDJ being used for Metaldyne gear evaluation study. • Results currently being analyzed by Metaldyne contracted gear expert. • Modules PCW & PDG to be sent to Metaldyne (Korea) for evaluation at HMC.

  6. Item 5 – Ground Gears EOL Test Result

  7. Item 5 – 4 Modules With Ground Gears PCW Ground Gears Typical Hob & Shave module PDG Ground Gears PDJ Ground Gears

  8. Item 6 – Deburr Process for X-fer Gear Set • Testing the effects of surface finish. • 3 Gear sets sent out to “REM Chemical” for Electro Chemical deburr treatment. Gears currently being processed. • Returned gear sets to be built up into modules and run over NVH EOL test stand. • Modules to be tested on HMC Theta engine at Roush. • Data to be analyzed and results shared.

  9. Item 7 – LMC & MMC Bearing Clearance Modules • 4 modules engineered by Fremont to provide LMC and MMC bearing clearances for transfer gear NVH sensitivity study. • 4 modules. • LMC: VUW & VUY • MMC: VVI & VVB • Modules tested across EOL NVH test stand. • Modules tested at Roush on Theta engine. • Work to correlate permanent EOL test stand at Fremont treated as the priority. Results analysis currently on-hold.

  10. Item 8 – Modules with Nissan TR BSM gears • 3 modules built at Fremont with transfer gears from one of Metaldyne’s other current production modules. • Also Hob & Shave production process. • Modules • UVS, URK, URJ. • Modules tested across EOL NVH test stand. • Modules tested at Roush on Theta engine. • Work to correlate permanent EOL test stand at Fremont treated as the priority. Results analysis currently on-hold.

  11. Item 9 - Test intrim EOL rejected modules at Plymouth for break-in run • Modules rejected at Fremont to be shipped to Plymouth for 1 hr Break-in. • Modules to be returned to Fremont for EOL re-test. • Break-in time sensitivity to be studied during process. • Testing complete. • Results documented in file“Before and After BI Results 072204.ppt” sent to HMC with 23 July 2004 weekly report.

  12. Item 11 – Actions From 9th July Meeting at HMC • Color maps & overall levels from EOL test, before and after break-in run. • Modules to be run across EOL test stand 16Jul04. • Modules to be given 1hr break-in run on the Theta engine at Roush. Speed sweep data also to be taken. • Re-test modules on EOL test stand at Fremont during week of 20th July. • Data analysis on-going • Reported last week • Reported last week • No Action required:- HMC action item.

  13. Item 11 – Next Steps - 10 HMC Returned Modules • 1 of 10 HMC Returned Modules • 1 of the 10 samples being returned is module FKP which was in the vehicle we rode in on July 9th that exhibited the “marginally acceptable” whine noise. Please note, that this was a P2 vehicle and was not equipped with the under hood beauty cover or engine noise treatments planned for production. As such, it should be noted that the noise level of this vehicle did not represent that of the current powertrain noise level. • Module tested on EOL NVH • Results documented in file“EOL whine testing vs engine testing.ppt” sent to HMC with 23 July 2004 weekly report. • 9 returned modules discussed in item 15.

  14. Ongoing Gear Noise Improvement Item 13 – Module with custom “round connector” shafts • Shafts designed to fit in current production module. • Prints submitted for fabrication. • Shafts currently being manufactured. Delay caused by material availability. • Shaft bearing journals will be ground, polished, and assembled at Fremont facility before EOL testing and engine testing. • Results to be analyzed and submitted to HMC on completion.

  15. Item 15 – Next Steps - 10 HMC Returned Modules • 9 of 10 HMC Returned Modules • 9 of the 10 modules used by HMC to develop the 0.65g acceptance criteria due at Plymouth week of 20 July 2004 • Modules being used for optimization of “permanent” NVH EOL test stand and correlation between test stand and HMC engine test results. • Testing & Data analysis on-going.

  16. Item 15 – Loose Sprocket Issue • “Torque break-away” and “thread lock” studies carried out by Metaldyne to verify root cause analysis, and possibe short term counter measures. • Results documented in file“Loose Nut Confirmation Testing 072104.ppt”sent to HMC with 23 July 2004 weekly report.

  17. Long Term NVH Improvement Plan - Status The following items have been prioritized based on the degree of improvement offered to the BSM, the likelihood of successful development / implementation, the amount of change to the product architecture, and the urgency of current gear whine issue resolution. • 1. Polymer gears – Development activity is underway for polymer gears for the transfer gear set. These gears will moulded to a metal hub with tooth geometries also part of the moulding process. Timing is on track to receive test parts mid-September. Successful testing of transfer gears will precede development of input gear mould tooling. • Ground transfer gears – Capacity of the gear grinding line has been reviewed and identified as feasible. Ground gears have been produced and testing on the Fremont EOL test machine & Theta engine at Roush. Two samples sent to HMC for validation.

  18. Long Term NVH Improvement Plan - Status • Remove heat treat from input gears – This activity was initiated and tested with 12.5° gears successfully. High speed durability testing at Metaldyne showed no significant signs of wear. Test modules were supplied to HMC for engine / vehicle testing as well. Next steps include testing of 31° gears with torsionally intensive durability test & cold testing at Metaldyne, and HMC validation testing. Metaldyne testing could be achieved within the HMC validation schedule if HMC agrees. • Transfer gear MOB increase – Based on recent measurements of transfer gear backlash levels, we are currently producing modules in the bottom ~25% of the running ranged proposed during our April ’04 meeting. Due to the recent change in helix angle from 12.5° to 31°, the gear supplier is still ramping up their production. Since we are attempting to build a bank to facilitate transferring our line to Korea, we are reluctant to interrupt their ramp-up activity until they reach full production levels.Data from EOL testing shows no significance to whine issue

  19. Long Term NVH Improvement Plan - Status • Revised helix angle for input gears – This activity is currently on hold pending gear supplier production status. Lessons learned from the 12.5° gear development revealed the need to test production intent manufacturing process as the prototype gears performed differently than gears made with the production process. Due to the recent change in helix angle from 12.5° to 31°, the gear supplier is still ramping up their production. Since we are attempting to build a bank to facilitate transferring our line to Korea, we are reluctant to interrupt their ramp-up activity until they reach full production levels. • Polymer gears (with internal damper) – This activity was initiated as part of the initial gear rattle problem investigation. It will continue pending development of item 1 and allocation of resources from other HMC urgent issues.

  20. Long Term NVH Improvement Plan - Status • Scissors gears – This activity is on hold based on the scope of development required to overcome known power consumption and gear whine issues as seen during initial development and allocation of resources from other HMC urgent issues. • Oil pump circuit sizing for increased drag torque – This activity is on hold based on the scope of development required to reconfigure the entire oil pump system allocation of resources from other HMC urgent issues. • Switch to World Engine Module – Same as above based on pending results.

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