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Design Team # 3Shell Eco Marathon (Super-mileage Car)
Members:Hussain Abdellatif Sohaib Syed AlamJulius Mantolino
Adam ProcterSupervisor:
Dr. Alex Kalamkarov
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Background Scope Design Requirements The Design Current Project Status Future Considerations Design Requirements Check Budget Acknowledgements
Outline
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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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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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Engine Fuel Injection System Powertrain
◦ Transmission◦ Bearings◦ Clutch
Chassis Wheels
The Design – Our Scope
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Rolling Resistance◦ Reduction in weight◦ More efficient wheels
Aerodynamics◦ Reduction in frontal area
The Design -Challenge
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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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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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One-way Needle Bearing
Reused electric motor from Yamaha
Gear reduction
Engine Modifications-Electric Starter
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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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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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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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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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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
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Fuel Pressurization System [5]
Fuel Delivery System-Pressurization
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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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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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Components:◦Gear Reduction Method Two Stages
◦Bearing◦Clutch
Powertrain
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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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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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Planetary Gearbox for 1st stage Roller Chain and Sprockets for 2nd stage
Powertrain - Overall
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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
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Centrifugal [7]
Friction Plate [8]
Powertrain-Clutch
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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
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Powertrain-Torque Calculations
Engine is not overloaded
0.00 5.00 10.00 15.00 20.00 25.00 30.000.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
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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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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Chassis – Rear Loading
Max. Stress: 55 MPa
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Chassis – Side Loading
Max. Stress: 75 MPa
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Chassis – Pull Loading
Max. Stress: 50 MPa
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Chassis – Push Loading
Max. Stress: 43.8 MPa
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Wheels
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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]
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3 wheels: 2 in front, 1 in back
Wheels
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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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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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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Wheels
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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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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
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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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Engine $425
Fuel Injection System $586
Drivetrain & Clutch (estimate) $2000
Chassis $500
Wheels $2500
--------------------------------------------- Total (15% Contingency) ~ $7000
Budget
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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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We Thank Our Sponsors
Acknowledgements - Sponsors
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[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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Questions ?
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Engine Specs Load Torque Assumptions Bearings Bearing, Output Shaft FEMS Starter Assembly FEM
Back Up Material
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Engine Specifications
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[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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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)
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Torque Calculations (3)
= 48.15 g,
, , [ref] [ref]
Engagement speed
SlipPeriod
Max. Clutch Torque
Clutch “Bites” Clutch transmits engine torque
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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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Power Train Stresses
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Starter Mount Stresses
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