Building prototype engines for test
Overview
This standard identifies the competences you need to carry out assembly operations to build prototype engines, in accordance with approved procedures. The engine you build will be used as a test engine to gain data on power characteristics, durability, emissions and performance, according to environment. All components assembled will be un-used and will have been produced for prototype application. You will be required to obtain all the required tools and equipment for the assembly operations, and to check that they are in a safe and usable condition.
In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various sub-assembly units and components into the engine major assembly. The assembly activities will also include making all necessary checks and adjustments, to ensure that components are correctly orientated, positioned and aligned, that moving parts have the correct working clearances, all fasteners are tightened to the correct torque, and that the assembled parts function as per the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work as a member of a team, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate assembly techniques and procedures for prototype vehicle engines. You will understand the engine being assembled, and its application, and will know about the equipment, relevant components and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly of the engine, especially those for lifting, handling and supporting the equipment being assembled. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
ensure that the specified components are available and that they are in a usable condition
assemble the components in their correct positions using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
the personal protective equipment and clothing (PPE) to be worn during the activities
the various types of assembly drawing and specification that are used during the assembly
- how to identify the components to be used; component identification systems (codes and component orientation indicators)
- preparations to be undertaken on the components, prior to fitting them into the assembly
- the assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used (jigs and fixtures)
- the various mechanical fasteners that will be used, and their method of installation (rivets, threaded fasteners, special securing devices)
- the importance of using the specified mechanical fastening devices for the assembly, and why you must not use substitutes
- how to complete basic fitting practices, meeting regulatory and organisational requirements (torque tightening; wire locking; fitting wire thread inserts; fitting o-ring seals; fitting lock nuts and swage nuts; lapping and blue bedding components)
- how to deal with components or fastening devices incorrectly assembled, damaged or having other faults
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced
- how to detect assembly defects, and what to do to rectify them (ineffective fasteners, foreign object damage)
- how to move large components, sub-assemblies and assemblies; the methods and equipment used to transport, handle and lift the components into position, and how to check that the equipment is within its current certification dates
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects
- the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the assembly activities
- problems with the assembly operations, and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the engine assembly activities:
- obtain and use the appropriate documentation (such as job instructions, engine assembly drawings, vehicle manuals, specifications, planning, quality control and other relevant documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain safe access and working arrangements for the work area, and ensure that any appropriate environmental conditions can be met
- check the calibration dates of tools and measuring instruments to be used
- use approved engine assembly techniques and procedures at all times
- ensure that the engine units are suitably supported and appropriate lifting and handling equipment is available
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- ensure that the required components are available and have the correct part numbers
- return all tools and equipment to the correct location on completion of the activities
- leave the work area in a safe and appropriate condition on completion of the activities
Assemble engines for one of the following types of prototype engines:
- petrol vee
- diesel vee
- hybrid (such as electric, LPG)
- petrol inline
- diesel inline
- rotary
Use ten of the following assembly methods and techniques:
- assembling components to sub-assembly level (such as piston assemblies, cylinder heads)
- drilling and riveting
- lapping/blue bedding of components (such as valves, bearings)
- assembling sub-assemblies to unit level
- positioning and aligning components
- earth bonding of components
applying gaskets and sealants/adhesives
tightening fastenings to the required torque
- assembling components having interference fits (such as by expansion, contraction, pressure)
- setting and adjusting components (such as liner protrusion, crankshaft float, working clearance)
- securing components using mechanical fasteners and threaded devices (such as circlips, pins)
- applying locking and retaining devices (such as circlips, pins, wire locking, lock nuts, stiff nuts, swage nuts)
- applying protection to openings to prevent entry of contaminating debris
- measuring of components using high precision measuring equipment (such as bar gauges, burette, bore gauge, micrometer, Vernier)
Build prototype engine assemblies by fitting seventeen of the following:
- cylinder block
- connecting rods
- sensing devices
- gearbox
- camshaft assemblies
- balancing mechanisms
- cylinder liners
- timing mechanisms
- shim buckets and shims
- cylinder heads
- injector mechanisms
- inlet manifolds
- crank shafts
- seals and gaskets
- pipe fittings/connectors
- fly wheel
- pulleys and sprockets
- filters
- torque converters
- belt, chains and gears
- instrumentation for data acquisition
- pistons and rings
- levers and linkages
- bearings (such as shell, ball and race, thrust)
- pumps (such as pressure, scavenge, fuel, oil, water)
- charging/starting components (such as alternators, starter motors, solenoids, magnetos)
- valve mechanisms (such as valves, guides, springs, collets)
- mechanical fasteners and mounting studs
Carry out the required inspections for accuracy, using the correct equipment, to include eight of the following:
- visual inspection for completeness and freedom from damage or foreign objects
- cylinder liner protrusion
- timing (such as valve, ignition, fuel injection)
- orientation
- operating/working clearance (such as valve)
- alignment
- belt/chain tension
- freedom of movement
- gear backlash
end float (such as crankshaft, camshaft, bearing)
torque loading of bolts
- checking for system blockages (such as oil and airways)
Check engine assemblies comply with one of the following:
- current industry standards, codes of practice and procedures
- customer standards and requirements
- engineer developed procedures
- specific engine requirement