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Mechanics

Oct 27, 2013 (4 years and 8 months ago)

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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

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
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

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

Theory Design 1 Design 2 Prototype Conclusion Questions

Manufactured by
HighLight

Industries

Houses original valves and
new water injector

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

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

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