Investigation of Fuel System Component O-Ring Interface Design & Assembly

Seals are commonly made by using o-rings in many liquid and gas filled system. Since the introduction of mini-concentric fuel pressure regulators mounted on fuel rails, issues have arisen related to assembly resulting in damage to the o-rings. The problem of damage o-rings can result in fuel leaks. The purpose of this study is to determine the optimum conditions in design/process to eliminate damage to the o-ring while maintaining sealability. A total of 14 variables were chosen to be examined in this study, 9 design related and 5 process related. To maximize the efficiency of testing, an orthogonal array was used to structure the experiment. After completing the study, assembly fixturing contributes 80% to successful assembly.