Development of a new pump through modifying a conventional automotive spark plug
A. Hambali
1*
, Z.A. Farid
1
and A.M. Najib
1
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Department of manufacturing design
Faculty of Manufacturing Engineering,
Universiti Teknikal Malaysia, Melaka
1200, Ayer Keroh 75450 Melaka
Tel: +606-3316019 Fax: +606-3316411
*Corresponding Author: hambali@utem.edu.my (A. Hambali)
Tel: +606-3316019 Fax: +606-3316411
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Abstract
A new pump has been described in this paper. The automotive spark plug is generally used for providing an electrode gap to produce an ignition to the vapor packed in fuel-air mixture. The reciprocating motion of the piston in combustion engine generates compressed air in the engine. Compressed air trapped between upper piston surface and spark plug which is positioned in the combustion chamber, can be utilized by modifying the spark plug design. This paper is focused on the utilization of compressed air trapped between upper piston surface and spark plug. Therefore, this paper describes an alternative function of automotive spark plug by modifying its design by implementing Pugh’s approach.
Keyword : Automotive spark plug, Pugh’s method
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1. Introduction
A spark plug as illustrated in Figure 1, is one of the easiest engine components to repair and an inexpensive one to replace. Fundamentally, the basic of a spark plug is that it must perform two primary functions, firstly, to ignite the air/fuel mixture and secondly, to remove the heat out of the combustion chamber (Khosla et al., 2005).
The spark plug is positioned in the combustion chamber at the point most suitable for igniting the compressed air-fuel mixture. It must, under all operating conditions, introduce the ignition energy into the combustion without developing a leak and without overheating (Anonymous, 2009).
The reciprocating motion of the piston in combustion engine generates compressed air in the engine. Compressed air trapped between upper piston surface and spark plug which is positioned in the combustion chamber can be utilized by modifying the spark plug design.
This paper is focused on the utilization of compressed air trapped between upper piston surface and spark plug
The idea behind the development and modification of the spark plug was based on the difficulties encountered by motorist facing with flat tire in the middle of nowhere, in which he or she has to push the motorbike to the nearest workshop. Even though there is equipment such as foot pump that has similar function, which is to inflate an inflatable item in the market, this invention has several advantages over the existing products. Thus, this paper discusses the alternative function of spark plugs which can be modified to be operated like a pump.
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2. The development of a new pump
Basically, the development of a new pump by modifying the existing spark plug is based on total design method or the Pugh’s method (Pugh, 1991). Generally, Pugh’s method is comprised six stages namely market (user need), product design specification (PDS), conceptual design, detail design, manufacture and sales as depicted in Figure 2. However, in this paper, the design process implemented to develop a new bump is started from the product design specification (PDS) to the conceptual design stage.
2.1 Product Design Specification (PDS)
Product design specification (PDS) is a document prepared early in the product development process that controls the design and manufacture of a product (Pugh, 1991).
The PDS is very important to the success of the product development process because it so influential in describing the requirement of the final component (Wright, 1998). In modifying and designing a new pump, 17 elements of the PDS were considered as depicted in Figure 3 which is illustrated as design requirements. The details of PDS are not discussed in this paper.
2.2
Concept development of a new pump at the conceptual design stage
The development of a new pump is designed and developed based on the scenario as depicted in Figure 4. Spark plug was modified to channel air from internal combustion engine.
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The reciprocating of pistons in combustion engine generates compressed air in the engine.
The compressed air was channelled out from the engine through modified spark plug. In order to use the modified spark plug or new pump, the engine must be kept on running.
2.3 Layout of Modified Spark Plug
A new pump or modified spark plug consists of a housing member, an ignition means, an air inlet member, a valve, a hose, and a clip. Air inlet member is securely held in the housing member, air clip is secured to an inflatable item and wherein the ignition means is connected via a wire to the air inlet member as illustrated in Figure 5.
2.4 How does it operate?
Firstly, an already connected spark plug is removed from a block engine of a motorcycle as illustrated in Figure 6a. Then, a new pump or modified spark plug is connected to the engine by conventional treading mechanism until it is securely held therein as displayed in
Figure 6b. The spark plug connector of the engine block is then connected to the modified spark plug via conventional manner. This unique configure will allow the engine of the motorcycle to operate in normal condition. The air clip is then connected to an inlet valve of any inflatable items as illustrated in Figure 6c. To inflate an inflatable item, the motorcycle is started by conventional method. This will result in the piston within the engine block to move conventional to create air pressure. Air is then flowed through the modified spark plug the hose into the inflatable item. The modified spark plug is required in order to ensure that the engine could be started easily. The amount of air or pressure
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flowing into the inflatable item could be either increased or decreased by increasing the stalled speed of the motorcycle. It must note that during this operation, motorcycle is not in a moving position as shown in Figure 6d. Some advantages of this new pump design or modified spark plug design are can deliver the compressed air in a very short time rely on the size of the inflatable items; portable and flexible due to its small size and light even can be put inside the in pocket and applicable for four-stroke and two stroke engines.
3. Conclusion
The paper presented the use of Pugh’s approach to develop and modifying automotive spark plug. The modified spark plug is used to inflate an inflatable item such as tyre, etc.
The main advantage of a pump is its size that was small enough to be put inside the pocket.
Moreover, the creation was very light in term of its weight that was contributed to the material used such as copper, and Teflon. This new pump or modified spark plug has a potential to be commercialized due to inexistence of similar product in the marketplace that offers small and light product of inflating the inflatable items. In fact, similar concept of invention with a few modifications can be used for other vehicles such as car, truck, van, and recreational vehicles.
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Acknowledgement
The authors wish to express our appreciation and gratitude to Mr Abd. Manan B Bustaman in giving us construction guide and ideas throughout this project. The authors also wish to thank Universiti Teknikal Malaysia Melaka (UTeM) for supporting this research.
References
Khosla, R. Howlett, R.J and Jain, L.C. (2005). Knowledge-Based Intelligent Information and Engineering Systems. Springer Science & Business, Australia, 964p
Anonymous, (2009). Automotive technical http://www.ultratunebrookvale.com. Accessed on 30 July 2009.
(spark plugs).
Pugh, S. (1991). Total Design: Integrated Methods for Successful Product Engineering.
Addison Wesley Limited, Wokingham, 278p.
Wright, I. (1998). Design Methods in Engineering and Production Design. McGraw-Hill.
London, 285p.
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