Sleeper6 wrote: Take for example the adjustment bolts on a B6 alternator, the front top bolt is easily accessed where-as the lower bolt head that also should be loosened is placed under the manifold? Sure it works and fits all your engineering requirements but it isn't very practical, why not put it on the proper belt side. Maybe thats just my un-educated common sense side talking, or maybe, just maybe its the resentment that someone else who also holds atleast a 4yr degree was so ignorant as to design something like that.
I think there’s a fundamental misunderstanding among some of the contributors to this conversation as to what an Engineer actually does and how a thing like an adjustment bracket is commissioned and designed. In the company I work for the Engineering group is fairly small. 8 people working on a wide variety of projects. In a case like that a single person often works on a project from beginning to end and is involved in most and sometimes all aspects of a design and the eventual creation of a final product.
But in the case of a company like Mazda and the design of a Car there are hundreds of people from Graphic Designers to Technologists to Engineers working in dozens of teams. When the engine group is TOLD by the Project Leader that they are using the B6 engine in the new MX-3 Precidia, it’s up to them to make things fit.
In the case of the guy who actually did design the adjustment bracket for that alternator you might think someone popped into his cubicle and said…”Hey Phil, we need an adjustment bracket for the alternator in the new MX-3 project. Can you whip something up for us?” In fact what likely happened, back in 1986 when it was first used on a first gen 323, is…
”Phil, we need you to design a bracket that will be used for the next 20 years, on every car the B series engine ever goes into, both RHD and LHD, FWD and AWD, B6, B8 and BP engines. It has to be simple and easy to use, low profile and have minimum moving parts.”
“And we need it by Friday.”
“And it has to cost less than $6.”
Then Phil has to calculate the design shear stress of the pivot and pinch bolts because a 12mm bolt costs $.05 more than a 10mm bolt and over the lifespan of the part number 5 or so million of them will be made and that extra nickel will add up to a wasted $250,000 which will cause his boss to fire him.
He needs to calculate the bending moment on the slider bracket, where the maximum bending moment occurs and at what belt tension and what safety factor to use because some moron with a crow bar might decide that the factory specs aren’t tight enough. If the bracket buckles his boss will fire him.
He needs to decide what materials to use and what torque spec to apply to the pivot bolt and the pinch bolt. Is the material of the alternator housing strong enough to withstand that torque value? If every end user on the planet strips the nut on their alternator his boss will fire him.
Then after he’s figured all that out he has to lay it out so that it will fit in a A-spec, E-spec and J-spec model. It has to fit with engines with EGR and without, SOHC and DOHC heads and all their intake manifold variations.
Any decently handy farmer can make a bracket that will fit his application and last 100 years out of angle iron and whatever hardware is laying about. An Engineer designs a bracket that is exactly as strong as it needs to be, costs as little as possible to manufacture and can be used in as many applications as the people who pay him want it to.