Design for complexity reduction of fuel sender assembly

James Greer, S. S. Rao, Li Chen, R. J. Cipra

Research output: Chapter in Book/Report/Conference proceedingConference contribution


This work presents a design methodology to address the complexity reduction of fuel-sender assembly. The current fuel-sender design is reviewed first by considering the present assembly, and then the complexity involved in the design and manufacturing processes are discussed. Using the current situation as the baseline, the proposed design is deployed for each subassembly of the fuel sender, along with parts manufacturability, assembly, and cost analyses, focusing on reducing the complexity of the fuel sender assembly. The group technology concepts are applied to the fuel level sensor, in which a shape factor and corresponding design control charts are defined and proposed for grouping particular fuel tank configurations with individual sensors. The optimum robust design techniques are considered for portions of the design proposed. Two goals are simultaneously targeted while satisfying the behavior constraints in the design phase. These goals are to reduce component cost, and to minimize the uncertainties associated with the manufacturing process. The results of the optimization analysis are used to produce the design drawings. The design proposed is intended as a first iteration, and will certainly be modified to become even more efficient in future iterations.

Original languageEnglish (US)
Title of host publication3rd Design for Manufacturing Conference
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791880340
StatePublished - 1998
Externally publishedYes
EventASME 1998 Design Engineering Technical Conferences, DETC 1998 - Atlanta, United States
Duration: Sep 13 1998Sep 16 1998

Publication series

NameProceedings of the ASME Design Engineering Technical Conference


ConferenceASME 1998 Design Engineering Technical Conferences, DETC 1998
Country/TerritoryUnited States

ASJC Scopus subject areas

  • Mechanical Engineering
  • Computer Graphics and Computer-Aided Design
  • Computer Science Applications
  • Modeling and Simulation


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