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BYU Emerging Market Engine Project

BYU Emerging Market Engine Project. The Challenge. Through an academic partnership called PACE, General Motors challenged us to design a low-cost, fuel-efficient vehicle for developing countries.

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BYU Emerging Market Engine Project

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  1. BYUEmerging Market EngineProject

  2. The Challenge Through an academic partnership called PACE, General Motors challenged us to design a low-cost, fuel-efficient vehicle for developing countries. Our sponsor, Belcan Engineering, Inc. provided funding, engineering support, and critical feedback throughout the project. http://www.businessweek.com/autos/autobeat/archives/GM%2520Logo.jpg http://www.belcan.com/companyinfo.php

  3. How do you design a car for better gas mileage? Reduce weight… …reduce drag… …use a more efficient power source… …reduce rolling resistance… …capture waste energy…

  4. Emerging Markets In 2008, 64 percent of GM’s sales occurred outside the United States, up from 59 percent the previous year. http://www.nytimes.com/2009/01/22/business/22auto.html

  5. Emerging Market Vehicle They want a vehicle that • …is economical • …is reliable. • …is comfortable and convenient. • …is environmentally responsible. Consumers in emerging markets • …value their hard-earned money. • …appreciate quality. • …are first-generation “middle class.” • …are getting tired of pollution.

  6. PACE Emerging Market Vehicle Specifications By July 2011, design and manufacture a vehicle which: • Sells for under $8,000 U.S. Dollars (2008) • Has excellent fuel economy (60 mpg) • Fully loaded weighs under 2,921 lb (1,325 kg ) • Cruises at 75 mph (120 km/h) on grades up to 3% • Is able to climb a 20% grade • Accelerates from 0-60 mph in 16 seconds • Has a driving range of 400 km (250 miles) • Meets Euro 5 (future) emissions standards

  7. EMV Project Schools

  8. Project Objective By March 25th 2009, define and build an engine prototype that produces 66 ft-lb. of torque and 65 hp brake power and achieves 60 miles per gallon (gasoline equivalent ) fuel economy. By July 20th 2009, validate the prototype’s performance through testing.

  9. The Competition

  10. Price (USD)

  11. Power (HP)

  12. Passenger Capacity

  13. Fuel Economy (MPG)

  14. Concept Generation Screening & Scoring Prototyping System Concept Fuel Concepts 16. Oil-actuated movable cams 1. Diesel/Bio Diesel 31. Parallel combustion – electric drive Regular Unleaded Gasoline 17. Variable Compression Ratio, movable compression chamber top 2. Compressed Air Pressure Engine 32. Cyclonic air filter to reduce intake pressure Compressed Natural Gas 18. Actively-tuned exhaust 3. Gasoline & Ethanol “flex” 33. Regenerative braking – compresses air, engine as compressor Diesel 19. Rotary valve train 34. Regenerative braking – compressed air 4. Compressed Natural Gas / Gasoline 35. Reduce exhaust pressure when braking 5. Multi-fuel Ethanol/Gasoline + LNG 20. Ball valve tappet “Flex” Gasoline / Ethanol Small Gasoline / Ethanol Engine 21. Coated rotary cams with adjustable timing 47. Regenerative braking – compressed air 6. Gasoline & Ethanol (separate tanks) 36. Ignition control (No throttle plate) 22. Heat transfer cylinder wall coating 37. Liquid nitrogen power 48. 6-cycle, air assist Mechanical Concepts 7. Natural Gas Turbocharger Integrated Starter 8. Gasoline/ Natural Gas Flex 23. Miller cycle valve train 38. Variable intake pressure Low-friction Wall Liner 9. Hydrogen Internal Combustion 30. Series combustion – electric drive 24. Alka-Seltzer engine 39. Variable valve timing, electric Direct Injection, Spark Ignition 10. Gasoline engine 25. Plug-in electric only 40. Variable valve timing, timing chain Heat Transfer Liner 11. Adjust cam for throttle 26. Fly wheel energy storage 41. Regenerative braking – rubber band Variable Cylinder Shutoff 12. Turbocharger and steam boiler 27. Mechanical variable cylinder shutoff (clutch mechanism) 42. Cylinder shutoff Direct Injection 13. High Pressure Boost Natural Gas at Home 43. Compressed air – fill at home 28. Steam turbine using exhaust waste heat 14. Direct Injection Spark Ignition Turbocharger 44. Regenerative braking - flywheel 29. Steam engine 15. Pancake griddle on exhaust manifold 45. Low-friction cylinder liner

  15. Power System Concept • Small engine (500-800 cc) • Turbocharger to increase power output • Direct injection to improve fuel efficiency • Gasoline / Ethanol for global fuel flexibility + + + Gasoline or Ethanol Small Engine Turbocharger Direct Injection

  16. 2008-2009 Prototype • BMW Motorcycle Engine (Rotax 654cc 1-cyl.) • Aerocharger Variable-Geometry Turbocharger • Use high octane fuel to simulate the effect of direct injection (high compression ratio) + + Rotax 654cc Aerocharger High Octane Gasoline

  17. How a Turbocharger Works A turbocharger uses energy from exhaust waste heat to force more air into the combustion chamber. http://www.aa1car.com/library/turbo_schematic.gif

  18. Power System Solution

  19. Control System The stock BMW engine control module (ECM) lacks important features required to run with a turbocharger. • No cam position sensor • No mass air flow sensor http://image.hondatuningmagazine.com/f/9329434/0704_ht_01_z+how_to_degree_a_camshaft+diagram.jpg http://www.aa1car.com/library/ford_maf_sensor.jpg

  20. Control System Manifold Pressure Sensor Throttle, TPS & Fuel Injector Mass Air Flow Sensor Exhaust Temp Sensor O2 Sensor Spark Plugs Engine Temp Sensor Crank Position Sensor Engine Control Module (ECM)

  21. Same as Published Specs? Meet Target? Test Engine without Turbo Test Engine with Turbo Modify Test Setup & Calibration The Experiment Modify Engine Map/ Turbo Tuning

  22. Fuel Economy Testing EPA City Fuel Economy Cycle (FTP 72) EPA Highway Fuel Economy Cycle (HWFET) http://www.dieselnet.com/standards/cycles/

  23. Test System Drive cycle tests are performed on sophisticated motoring chassis dynamometers using complete vehicles. No test system available at BYU No vehicle http://www.autoequipexpo.com.au/xerxes/UserFiles/AutoEquipExpoandConvention/sydney08/dynamometer.jpg

  24. Test System Solution

  25. Steady-State Approximation of EPA Highway Fuel Economy Test Driving Schedule http://fueleconomy.gov/feg/images/hwfetdds.gif

  26. Fuel Consumption Data

  27. Transmission Approximation • Model Assumptions: • Transmission is 85% efficient • Engine always at 3200 rpm • Vehicle + Driver weight = 2000 lbs. • Rolling Resistance coefficient = 0.025 • Frontal Area * Drag coefficient = 7 ft2 Estimated Highway Fuel Economy (no turbocharger): 54 mpg

  28. Moving Forward… By tuning the turbocharger and control system: • We expect more torque at every RPM. • We expect to maintain fuel economy. Next year, when we add direct injection, we expect to increase fuel economy to 60 mpg.

  29. Conclusion With continued testing and tuning, we look forward to demonstrating the feasibility of the EME concept power system. Eventually, the engine design will be incorporated into the PACE Emerging Market Vehicle.

  30. Questions/Comments

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