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flinkexistenceΜηχανική

27 Οκτ 2013 (πριν από 3 χρόνια και 5 μήνες)

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Team 6 Stroke

Tim
Opperwall
, John Mantel, Andrew
DeJong
, Marc
Eberlein
, Jim
VanLeeuwen


6 Stroke Engine Theory



Design Alternatives

1.
Cam

2.
Engine Control Unit (ECU)



Prototype Testing



Conclusions



Questions






Outline

1. Intake

2. Compression

3. Combustion

4. Exhaust

5. Water Injection

6. Exhaust

Theory

Design 1 Design 2 Prototype Conclusion Questions

4 Stroke Engine

6 Stroke Engine

1. Intake

Theory

Design 1 Design 2 Prototype Conclusion Questions

2. Compression

Theory

Design 1 Design 2 Prototype Conclusion Questions

3. Combustion

Theory

Design 1 Design 2 Prototype Conclusion Questions

4. Exhaust

Theory

Design 1 Design 2 Prototype Conclusion Questions

5. Water Injection

Theory

Design 1 Design 2 Prototype Conclusion Questions

6. Re
-
Exhaust

Theory

Design 1 Design 2 Prototype Conclusion Questions

Q
out,water

Q
out,exhaust

Q
in,gasoline

W
stroke
-
3

W
stroke
-
5

Thermodynamics

Theory

Design 1 Design 2 Prototype Conclusion Questions


Patent for 6
-
Stroke I.C. Engine


May 4, 1920 Leonard H Dyer


Basic idea of using a water injecting fifth stroke to increase
efficiency and simplify the cooling of an internal combustion
engine.


‘Crower Engine’


2004 Bruce Crower


Few calculations, but working prototype


Senior Design


2009
-
10 Team 14


Continued development


Precedence

Theory

Design 1 Design 2 Prototype Conclusion Questions


Team interests


Engines


Energy efficiency




Challenging project




New ideas




Motivation

Theory

Design 1 Design 2 Prototype Conclusion Questions


Design a 6 Stroke Engine



Manufacture a 6 Stroke Engine



Transparency



Stewardship



Safety

Design Goals and Norms

Theory

Design 1 Design 2 Prototype Conclusion Questions


Lotus Simulation


Model single cylinder engine


Fully customizable


Helped approximate internal pressures
and temperatures


4 Stroke Engine Modeling

Theory

Design 1 Design 2 Prototype Conclusion Questions


EES Calculations


Determines combustion
composition


Temperature, pressure,
enthalpy, and entropy at
each state point


h_air
[3]=x_co2[3]*enthalpy(co2,t=T[3])+x_n2[3]*enthalpy(n2,t=T[3])


+x_o2[3]*enthalpy(o2,t=T[3])+x_h2o[3]*enthalpy(h2o,t=T[3])

6 Stroke Engine Modeling

Theory

Design 1 Design 2 Prototype Conclusion Questions

1.
Camshaft Modification



Mechanically controlled


Extend crankcase to allow room


Manufacture camshaft

2.
Electrically Controlled Engine


Program engine control unit (ECU)


Remove cam controlled valves


Replace with solenoid actuated valves


Added capability between 4+6 strokes


Head redesign




Design Alternatives

Theory

Design 1 Design 2 Prototype Conclusion Questions

Camshaft

Switch

Spark Plug

Flywheel

Pushrods

Valves

Injector

Theory Design 1 Design 2 Prototype Conclusion Questions

Cam Design: Overview

The designed six stroke camshaft.

Intake Cam

Exhaust Cam

Measured 4
-
stroke Camshaft

Cam Design: Timing

Intake Cam

Exhaust Cam

Injector Cam

Gear to
Reduction Shaft

Theory Design 1 Design 2 Prototype Conclusion Questions

Speed Sensors

ECU Brain

Relays

Injector

Solenoids

Valves

Theory Design 1 Design 2 Prototype Conclusion Questions

Spark Plug

Flywheel

ECU Design: Overview

Thermocouple

The 1000 tooth encoder
used to communicate
engine speed to the ECU.

The optical sensor sends
high signal every top dead
center (TDC).

ECU Design: Speed Sensors

Theory Design 1 Design 2 Prototype Conclusion Questions

ECU Design: Brain

Speed Sensor
Input

Engine Speed
and Position

Valve and
Injector Output

Thermocouple

Engine
Temperature

Theory Design 1 Design 2 Prototype Conclusion Questions

The original valve lift profile.

ECU Design: Original Timing

Theory Design 1 Design 2 Prototype Conclusion Questions

ECU Design: Brain Timing

Theory Design 1 Design 2 Prototype Conclusion Questions

ECU Design: Relays

Theory Design 1 Design 2 Prototype Conclusion Questions


Few solenoids meet both force and speed requirements

Calculations for the required
force to open the exhaust.

Calculation for the
required stroke time.

ECU Design: Solenoids

Theory Design 1 Design 2 Prototype Conclusion Questions

Core

Valve Closing
Solenoid

Valve Opening
Solenoid

Valve

ECU Design: Solenoids

Theory Design 1 Design 2 Prototype Conclusion Questions


Solenoid mounting system


Laser
-
cut brackets


Adjustability


Threaded Rod


Mounts to new head

ECU Design: Solenoids

Theory Design 1 Design 2 Prototype Conclusion Questions

ECU Design: Spring

Theory Design 1 Design 2 Prototype Conclusion Questions

ECU Design: Spring

Theory Design 1 Design 2 Prototype Conclusion Questions

The GDI injector chosen to inject water during the fifth stroke.

ECU Design: Water Injection

100psi air

injector

Theory Design 1 Design 2 Prototype Conclusion Questions

Pushrod
Location

Spark Plug
Location

The original head for the engine.

Valve Stem
Location

ECU Design: Head

Theory Design 1 Design 2 Prototype Conclusion Questions


Head design and fabrication


Drawn up in AutoCAD


Manufactured by
HighLight

Industries


Houses original valves and
new water injector


ECU Design: Head

Theory Design 1 Design 2 Prototype Conclusion Questions

Valve Location

Water Injector

Spark Plug

Theory Design 1 Design 2 Prototype Conclusion Questions



Complete design for cam shaft alternative



Complete design for ECU alternative



Prototype sustained multiple combustions


Single hardware limitation


Theory Design 1 Design 2 Prototype Conclusion Questions

Conclusion: Goals



Inadequate parts limit engine performance



No EE’s on team



Seeing the big picture




Conclusion: Obstacles

Theory Design 1 Design 2 Prototype Conclusion Questions



Applied thermodynamics



Prototyping



Troubleshooting



Team management


Conclusion: Lessons

Theory Design 1 Design 2 Prototype Conclusion Questions


Professor Nielson


Team Advisor



Ren

Tubergen



Industrial Consultant



Nick
Hendriksma



Team Mentor



Professor
VanderLeest
, Professor
Brouwer
, and Paul
Bloem



Electronic troubleshooting help



Phil
Jasperse



Machine shop



Highlight Industries


Machine shop



Conclusion: Acknowledgements

Theory Design 1 Design 2 Prototype Conclusion Questions