design team # 3 shell eco marathon ( super-mileage car)

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Design Team # 3 Shell Eco Marathon (Super-mileage Car) Members: Hussain Abdellatif Sohaib Syed Alam Julius Mantolino Adam Procter Supervisor: Dr. Alex Kalamkarov

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Design Team # 3 Shell Eco Marathon ( Super-mileage Car). Members: Hussain Abdellatif Sohaib Syed Alam Julius Mantolino Adam Procter Supervisor: Dr. Alex Kalamkarov. Outline. Background Scope Design Requirements The Design Current Project Status Future Considerations - PowerPoint PPT Presentation

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Page 1: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Design Team # 3Shell Eco Marathon (Super-mileage Car)

Members:Hussain Abdellatif Sohaib Syed AlamJulius Mantolino

Adam ProcterSupervisor:

Dr. Alex Kalamkarov

Page 2: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Background Scope Design Requirements The Design Current Project Status Future Considerations Design Requirements Check Budget Acknowledgements

Outline

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Page 3: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Americas Shell Eco-Marathon Competitionnot to go fast but to use least amount of fuel Houston, Texas – (March 29-April 1 2012) 2009 Dalhousie Team - 12th Place (819mpg) Core Super mileage Team with 4 volunteers

◦ Cover◦ Steering◦ Driver

Background

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Page 4: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Ultimate Goal: Achieve ≥ 900 mpg Qualify/Compete for Shell Eco Marathon:

◦ Geometric Limitations ◦ 4 stroke IC Gasoline Engine

Increased Fuel Efficiency Lighter Powertrain Lighter Chassis Lighter & More Efficient Wheels

Design Requirements

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Page 5: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Engine Fuel Injection System Powertrain

◦ Transmission◦ Bearings◦ Clutch

Chassis Wheels

The Design – Our Scope

5

Page 6: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Rolling Resistance◦ Reduction in weight◦ More efficient wheels

Aerodynamics◦ Reduction in frontal area

The Design -Challenge

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Page 7: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Direct Fuel Consumption Options Considered:

◦ Old 35cc Honda◦ Old 50cc XF Yamaha ◦ New 35cc Robin Subaru

Honda 35cc [1]

Robin Subaru 35cc [2]

50cc XF Yamaha

Engine

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Page 8: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Parameter 35cc Honda[1] 35cc Subaru[2] 50cc Yamaha[3]

Weight [kg] 3.00 2.80 11.34

Displacement [cm3] 35.8 33.5 49

Max. Power [HP @ RPM]

1.3 @ 7000 1.6 @ 7000 5 @ 8000

Max. Torque [Nm @ RPM]

1.6 @ 5500 1.76 @ 5000 4.6 @ 6500

Max. Power to Weight Ratio [HP/kg]

0.43 0.57 0.44

Past Experience Underpowered N/A Overpowered

Engine Selected : 35cc Robin Subaru

Engine - Selection

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Page 9: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

One-way Needle Bearing

Reused electric motor from Yamaha

Gear reduction

Engine Modifications-Electric Starter

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Page 10: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Requirement: Max. Noise Level <90 dB

Stock Muffler:◦ Lower Efficiency

Glass Pack Muffler:◦ Perforated Design◦ Packing diffuses sound◦ Less restriction Glass Pack Muffler

[4]

Engine Modifications-Muffler

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Page 11: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Possible fuel delivery methods:◦ Carbureted◦ Port Fuel Injection◦ Direct Injection

Direct Injection is not Viable:◦ Requires mechanical fuel pump (competition

rules)◦ Complex

Fuel Delivery System

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Page 12: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Carburetor Port Fuel Injection

Advantages No cost Time savings

Advantages Controlled amounts of fuel Conversion kit can be readily

purchasedDisadvantages Low efficiency No control on optimum fuel

consumption

Disadvantages Cost (~$800) Needs pressurized system Calibration and fine tuning

Selected: Port Fuel Injection

Fuel Delivery System-Selection

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Page 13: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Replace carburetor Conversion kit purchased from Ecotron: Key components:

◦Oxygen (O2) Sensor◦Fuel Injector◦Programmable Engine Control Unit (ECU)◦Fuel Pressurization System◦Throttle Body

Fuel Delivery System-Electronic Fuel Injection

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Page 14: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Control parameters as required

Engine Control Unit (ECU)

Throttle Position

Inlet Air Pressure

Fuel Injector

Inlet Air Temp.

Exhaust Temp.

Crankshaft Position

Engine Kill Switch

Programmable Control

Parameters

Sensors – Input Controlled Output

Exhaust O2

Fuel Delivery System-Electronic Fuel Injection

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Spark Timing

Page 15: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Fuel Pressurization System [5]

Fuel Delivery System-Pressurization

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Page 16: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Transmits power from engine Require minimum power losses Provide sufficient torque Best Efficiency Point (BEP) ∼ 5000 RPM

◦ Provided by bsfc curve◦ To be verified with testing

Calculate suitable gear ratio:

Powertrain

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Page 17: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Direct Drive Variable Transmission

Advantages: Simple design Cheap Lightweight

Advantages: Vary the gear ratio to the wheel Change torque at wheel

Disadvantages: Can’t run at BEP Start-up load

Disadvantages: Expensive Complicated and heavy Requires gear shifting

Transmission Type Selected : Direct Drive

Powertrain- Transmission

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Page 18: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Components:◦Gear Reduction Method Two Stages

◦Bearing◦Clutch

Powertrain

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Page 19: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Roller Chain Timing Belt Planetary Gearbox

Advantages: Easy to design Cheap

Advantages: Cheap Light weight

Advantages: Compact Design High reliability

Disadvantages: Weight Large sprockets Space

Disadvantages: Pulleys sizes Space

Disadvantages: Cost (~$800) Medium Weight

Primary Stage Selected : Planetary Gearbox

Powertrain – 1st Stage

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Page 20: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Planetary Gearbox for 1st stage Purchase Neugart PLE60-20 Planetary

Gearbox from Wainbee Ltd.◦ 94% efficient◦ 20:1 gear ratio◦ Continuous torque 44 N.m.

Roller Chain and Sprockets for 2nd stage

Powertrain - Overall

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Page 21: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Planetary Gearbox for 1st stage Roller Chain and Sprockets for 2nd stage

Powertrain - Overall

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Page 22: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Powertrain - Bearings

Ceramic (Si3N4) Ball Bearings [6] Steel Bearings

Advantages:

Significantly reduced weight;

(0.5 x steel)

30% the friction of steel

Provides smoother operation

Advantages:

Cheap

Disadvantages:

Expensive (10 x price of steel)

Disadvantages:

Heavier

More friction

Requires lubrication

Bearings Selected : Ceramic Ball Bearings22

Page 23: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Centrifugal [7]

Friction Plate [8]

Powertrain-Clutch

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Page 24: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Powertrain-Clutch Selection

Friction Plate Clutch Centrifugal Clutch

Advantages:

Flexibility in engaging

Less power losses

Greater torque capacity

Advantages:

Light weight Compact

Automatic engagement

Disadvantages:

Heavier

Space

Risk of stalling  

Disadvantages:

Power losses during slippage

Spares

Clutch Selected : Centrifugal Clutch24

Page 25: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Powertrain-Torque Calculations

Engine is not overloaded

0.00 5.00 10.00 15.00 20.00 25.00 30.000.000.050.100.150.200.250.300.350.400.45

Torque@ Clutch Vs. Car Speed (with G = 20)

Car Speed (mph)

Torq

ue @

Clu

tch

(Nm

)

0.00 5.00 10.00 15.00 20.00 25.00 30.000.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

Power@ Clutch Vs. Car Speed

Car Speed (mph)

Pow

er (

hp)

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Page 26: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Design Requirement: Lighter chassis◦ Aluminum Alloy 6061-T6◦ Yield strength = 275 MPa

Weight estimate entire car (with driver) ~ 90kg

Withstand static load of 700N on roll bar

Chassis-Selection

Past team Selected• 1’’ OD by 0.125” thick• Cross section area = 0.34 in2

• 1-1/4’’ OD by 0.065” thick• Cross section area = 0.24 in2

30% weight reduction per unit length

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Page 27: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Chassis – Rear Loading

Max. Stress: 55 MPa

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Page 28: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Chassis – Side Loading

Max. Stress: 75 MPa

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Page 29: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Chassis – Pull Loading

Max. Stress: 50 MPa

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Page 30: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Chassis – Push Loading

Max. Stress: 43.8 MPa

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Page 31: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Wheels

31

3 wheels: 2 in front, 1 in back

Front Wheel Design◦ Lighter◦ No Internal Ratchet

Back Wheel Design◦ Internal Ratchet◦ Heavier

Back vs Front Wheel Assembly [9]

Page 32: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

3 wheels: 2 in front, 1 in backWheels

Past team Selected• Front Wheels:

o Small (406 x 44c)• Back wheels:

o Small (406 x 44c)o Back Wheel Design

• Front wheels:o Larger (700 x 25c)

• Back wheels:o Larger (650 x 25c)o Front Wheel Design

Front Wheel Assembly:• Lighter

Larger Rim Size:• Less Bearing Loss

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Page 33: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Incorporate Sprag Clutch in Back Wheel

Disc Brakes:◦ Reusing from past team◦ Consistent brake performance

Hubs & Spokes to be purchased

Wheels

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Page 34: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Past:◦ Michelin road tires

Selected:◦ Continental GatorSkin tires◦ Higher inflation pressure

150 psi vs. 60 psi Lower rolling resistance

◦ Flat and puncture resistant◦ Durable

Wheels

Michelin Tires [10]

GatorSkin Tire [11]

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Page 35: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Wheels

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Page 36: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Purchased:◦ Robin Subaru 33.5cc engine◦ Electronic Fuel Injection (EFI) kit◦ PLE60-20 Planetary Gearbox◦ Aluminum tubing for chassis

Designed:◦ Power Train Components◦ Electric Starter Assembly◦ Chassis Main Frame Body

Project Status

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Page 37: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Achieved Already Qualify/Compete for Shell Eco Marathon

◦ Geometric Limitations◦ 4 stroke IC Gasoline Engine

Lighter Powertrain (Centrifugal) Lighter Chassis (30% reduction)To Be Achieved: Increased Fuel Efficiency - to be confirmed with dyno Lighter & More Efficient Wheels Achieve ≥ 900 mpg - TBD

Design Req. Check

37

Page 38: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Assemble Power Train Assemble Power Train, Steering & Cover

onto Chassis Purchase Wheels & Wheel Components Obtain Engine Curves with Dyno:

◦ Carburetor◦ Fuel Injection

Fine Tune ECU Programmable Parameters Dyno Vehicle @ Wheels

Future Considerations

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Page 39: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Engine $425 Fuel Injection System $586 Drivetrain & Clutch (estimate) $2000 Chassis $500 Wheels $2500--------------------------------------------- Total (15% Contingency) ~ $7000

Budget

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Page 40: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

We would like to thank: Dr. Julio Militzer Dr. Alex Kalamkarov Albert Murphy Mark MacDonald Angus MacPherson Peter Jones Allison Chua, Drew Moores, Ryan Louie &

Dainis Nams

Acknowledgments

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Page 41: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

We Thank Our Sponsors

Acknowledgements - Sponsors

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Page 42: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

[1] http://robinamerica.com/pspecsheet [2] http://www.baileysonline.com/itemdetail[3] http://www.elsberg-tuning.dk/yamaha.html[4] http://auto.howstuffworks.com/muffler5.htm[5] http://poisson.me.dal.ca/~dp_09_15/docs/Fall%20Build%20Report.pdf[6] http://www.vxb.com/page/bearings/CTGY/CeramicBallBearings[7] http://auto.howstuffworks.com/clutch1.htm[8] http://auto.howstuffworks.com/clutch1.htm[9] http://www.qbike.com/cgi-bin/find.cgi?st=road+wheel[10] http://www.michelin.ca/[11]

http://www.mec.ca/AST/ShopMEC/Cycling/TiresTubesWheels/RoadTires/PRD~5005-157/continental-ultra-gatorskin-700-x-28-wire-tire.jsp

References

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Page 43: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Questions ?

43

Page 44: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Engine Specs Load Torque Assumptions Bearings Bearing, Output Shaft FEMS Starter Assembly FEM

Back Up Material

44

Page 45: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Engine Specifications

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Page 46: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

[ref] – common CD used in old 90’s cars - the max. allowed in competition - frontal area of around (19inx28in)

Torque Calculations (1)

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Page 47: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Torque Calculations (2)

0.00 5.00 10.00 15.00 20.00 25.00 30.000.000

1.000

2.000

3.000

4.000

5.000

6.000

Torque Load @ Wheel Vs. Car Speed

RollDrag

Car Speed (mph)

Torq

ue (N

m)

47

Page 48: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Torque Calculations (3)

= 48.15 g,  

, , [ref] [ref]

Engagement speed

SlipPeriod

Max. Clutch Torque

Clutch “Bites” Clutch transmits engine torque

48

Page 49: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

BearingsCeramic (Si3N4) Ball Bearings Steel Bearings

Advantages:

Significantly reduced weight; density of

Si3N4 is 3.2 g/cm3 versus 7.8 g/cm3 of steel

Co-efficient of friction is 30% that of steel

Less lubrication required Can operate at

higher speeds (20% to 40% higher)

Smoother operation because modulus of

elasticity higher (stiffer) than steel; 320 GPa

vs 200 GPa – less deformations leading to

less vibrations

Advantages:

Cheap

Better impact loading handling

Disadvantages:

Expensive (10 times the cost of steel

bearings)

Disadvantages:

Heavier

Higher co-efficient of friction

Need for lubrication

More vibrations and rocky operation

Ball Bearings Selected : Ceramic Ball Bearings

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Page 50: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Power Train Stresses

50

Page 51: Design Team # 3 Shell Eco Marathon  ( Super-mileage Car)

Starter Mount Stresses

51