Hanon Systems Internship 2016

Zach Bowling
August 3rd, 2016

Confidentiality Notice: This document contains confidential or legally privileged information. You are hereby notified that any disclosure, copying, distribution
or reliance upon the contents of this document is strictly prohibited without prior written Hanon Systems’ authorization.
 Introduction

• Education
– Michigan State University
• Major: Mechanical Engineering
• Incoming Junior
– Graduated Detroit Catholic Central in 2014
• Job
– 2nd year working at Hanon
– ATC Compressors Intern
• Hobbies
– Playing guitar and drums
– Camping, hiking, kayaking etc.
– Attending as many concerts as possible

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 First Month (May 16th - June 16th)

• Took Compressor Part Inventory in Proto Lab

– ~130 different parts, hundreds of each
• Updated individual part information in VLIMS with
more accurate descriptions
• Cleaned, oiled, and measured compressor
components for future builds
• Attended several intern training sessions detailing the
various product groups
• Refreshed and enhanced knowledge of the A/C loop in
order to run tests
• Trained on compressor stand and began running NVH
tests for FCA compressors

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 Compressor NVH Testing

• Ran 1-2 pumps a day when possible

• Verified proper charge by checking for ~5°C sub-cool
• Set pressure and rpm conditions for four different OEM
specified tests

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 Compressor NVH Testing
1. Force Test
– Stabilize at Pd = 246 psig, Ps = 29 psig
– Ramp 1000-4000 rpm over 3 minutes
2. Pulsation test [max displacement]
– Stabilize at Pd = 218psig, Ps = 29 psig
– Ramp 1000-4000 rpm over three minutes
– Three 10s steady-state recordings at 1000, 2000, 3000 rpm
3. Pulsation Test [mid displacement]
– Stabilize at Pd = 145 psig, 1000rpm
– ECV current ramped up from 0.3-0.5A over 3 minutes
– ECV current ramped down from 0.5-0.3A over 3 minutes
4. Clutch engagement test
– Engage clutch after 10s recording, disengage after 35s

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 2nd Month (June 17th - July 17th)
• Continued to run compressor NVH stand
– Continuous issues resulted in delays
• Attended a Tigers game for intern bonding
• Began performing pulley run-out testing

-Set up and ran NVH testing on two

“B-Car” HVACs
• Mounted HVAC case, hooked up wires,
and properly placed data acquisition
tools (mics, tachometer, voltammeter etc)
• Controlled actuators to take recordings
of different modes and door sweeps

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 NVH Compressor Stand Issues

• “Frankenstein Stand”
• Test specifications provided, no stand specifications
– HVAC blower burned out when current was too high
• Acquired new fan, labeled controller with max conditions
– No standard for changing out pumps
• System was accidentally over-charged

• Scheduling overlaps
• Transducer failures
• Leaks

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 Pulley Run-Out Testing

• Created an Excel template to record measurements

• Measured max axial and radial pulley displacement
– Averaged measurements of front, middle, and rear grooves
• Completed 45 pumps to date, 30 left*
• Five pump models tested:
1. GMET
2. Pentastar
3. Pentastar BSG
4. 2.2L DSL*
5. 3.0L DSL*

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 3rd Month (July 18th – August 19th)

• Set up and ran two “C-Car” HVAC NVH tests

– Same process as B-Car HVACs, different rig
• Ongoing work of NVH and pulley run-out testing
• Driving vehicles to and from Ford for testing
• In the process of acquiring a more efficient
measurement data acquisition system for the proto lab

Wireless / Direct
Ball Pocket Length / Piston End
Cable Data Transfer
Length Gauges
Shoe to Shoe Gauge
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 Takeaways

• Invaluable Experience
– Hands on lab work
– Corporate communication
– Problem solving
• Fantastic Work Environment
• Intern Classes and Events
• Great Co-Workers

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Thank You
Accelerating Innovation

www.hanonsystems.com
Strictly private and confidential