Development of a functional prototype (up to B-sample maturity) for a hydrogen fuel rail for a heavy-duty internal combustion engine. The fuel injection system was based on Port Fuel Injection (PFI).
- Identification of the key requirements derived from the specific application as well as from regulatory constraints
- Definition of:
- a suitable layout and overall design within the available installation space
- manufacturing processes for individual components and the assembled fuel rail, taking into account specific requirements resulting from the use in a hydrogen application
- achievable tolerances for connection interfaces and for the overall assembly
- feasible residual contamination (cleanliness) requirements
- Definition of a design concept based on injector interfaces (“injector receptacles”)
- Design and preparation of manufacturing documentation for different volume variants and injector configurations
- Execution of brazing trials to determine the required process parameters
- Participation in D-FMEA and P-FMEA activities to validate and safeguard both design and manufacturing process
- Design and preparation of manufacturing documentation for test setups (validation), tools, and fixtures
- Continuous coordination with the OEM, prototype manufacturing, suppliers, and other project stakeholders
- Project documentation in accordance with IATF requirements up to B-sample maturity
