SAE Eco-Marathon. By Travis Moore, Nikolaus Glassy, John Gamble, and Abdulrahman Alshodokhi Team 14

Transcription

1 SAE Ec-Marathn By Travis Mre, Niklaus Glassy, Jhn Gamble, and Abdulrahman Alshdkhi Team 14 Prject Frmulatin and Prject Plan Dcument Submitted twards partial fulfillment f the requirements fr Mechanical Engineering Design I Fall 2013 Department f Mechanical Engineering Nrthern Arizna University Flagstaff, AZ 86011

2 Cntents PROJECT DESCRIPTION... 3 Need Statement:... 3 OBJECTIVE... 3 Gal:... 3 BACKGROUND... 4 OPERATING ENVIRONMENT... 4 DESIGN CONSTRAINTS... 5 Drive train Cnstraints (Transmissin & Clutch):... 5 Braking Cnstraints:... 6 Fuel System Cnstraints:... 6 Electrical System Cnstraints:... 7 Technical Dcumentatin Cnstraints:... 7 PLANNING... 8 Quality Functin Develpment:... 8 CONCLUSION:... 8 REFERENCES... 9 APPENDIES Appendix A: Gantt Chart Appendix B: QFD Chart

3 PROJECT DESCRIPTION Need Statement: Due t the significant number f vehicles running n finite resurces as a means f transprtatin, it has becme necessary t research and develp means t stretch thse finite resurces further. The Shell Crpratin has spnsred a cmpetitin t prmte this research and develpment in the field f fuel efficiency. The scpe f this prject is t design, build, test, and present a vehicle that cnfrms t the set requirements and cnstraints t prduce a vehicle that will prduce extremely high fuel efficiency. OBJECTIVE The bjective f this team fr the verall prject is t design prpulsin, braking, and electrical systems fr a vehicle that will safely: Start-up and engine at desired rpm within 5 secnds Achieve a maximum average speed f 17mph Stp the vehicle within 50ft frm a speed f 17mph Hld a vehicle statinary n a 20% incline Cmpletely shut dwn all vehicle systems within 1 secnd Gal: The team s gal fr this semester is t accurately and apprpriately design an internal cmbustin engine pwered vehicle fr the Shell Ec-Marathn Cmpetitin that will have several subsystems wrking tgether t reach a fuel efficiency f at least 500 mpg. The team will be fcusing n the pwer train, fuel, electrical, braking and the technical dcumentatin fr the cmpetitin. The team will wrk in cnjunctin with anther team frm Nrthern Arizna University (NAU) that will be wrking n the remaining systems t cmplete the vehicle design. 3

4 BACKGROUND One f the biggest prblems in tday s sciety is the quest t stretch the use f finite resurces. One applicatin in specific is designing a vehicle that maximizes the vehicle s fuel efficiency. The mre fuel efficient that vehicles can be designed means that the cnsumptin rate f finite resurces will decrease, prviding a lnger use-time f said finite resurce. The main finite resurce that is shwing t be prblematic is fssil fuels. With reserves having decreasing standing levels, the price required t acquire these fssil fuels is increasing. This related directly t the prices shwn at fuel pumps. The Shell Crpratin puts n a cmpetitin, knwn as the Shell Ec-Marathn, t have engineering students frm arund the wrld design and build a vehicle that prduces extremely high fuel efficiencies. The cmpetitin riginally started in 1939 as a bet between 2 Shell engineers. Over time it evlved int an internatinal cmpetitin with events held in Eurpe, the Americas, and Asia. Starting in 2007, a cmpetitin was held in the United States, frm that pint, clleges in the US were able t cmpete. The Shell Crpratin hpes that this cmpetitin will help spur new and cutting edge vehicle designs and vehicle systems. OPERATING ENVIRONMENT Our perating envirnment can be brken int 4 main sectins: design, build, test, and cmpetitin. The bulk f design and fabricatin wrk will be dne at the NAU campus in Flagstaff, AZ. The design wrk will cnsist f weekly grup and team meetings. This is t insure that all f the team s member s independent wrk will be apprpriate t the verall design and has yielded accurate results. All f the fabricatin f the design vehicle will be dne at the student build shp lcated n the NAU campus. This is where the design vehicle will take frm, having all f the separate systems cming tgether. The team will assemble rdered parts, fabricate custm parts, and install systems n the vehicle. The initial engine break perid will be 4

5 held here. The team s drivers will als gain experience driving and perating the integrated systems in the vehicle t ensure they are easy t perate. The team will perfrm initial quality tests in Flagstaff, but will travel dwn t Phenix, AZ t get a mre accurate tune fr the cmpetitin lcatin. Since the cmpetitin is lcated in Hustn, TX, elevatin 43 feet abve sea level, tuning the vehicle fr Flagstaff s elevatin f 7000 feet abve sea level wuld nt yield the best engine efficiency results cme cmpetitin. Thus, the team will take the vehicle and tune it t an elevatin f 1200 feet abve sea level in Phenix. The reasning behind this is s that there will nt be a severe change in tuning as cmpared t an extremely high elevatin f 7000 feet. The final perating envirnment will be the Shell Ec-Marathn Cmpetitin lcated in dwntwn Hustn. Here the vehicle will be tuned and have several practice laps befre the actual cmpetitin. This is als where the team will present the technical dcumentatin fr the vehicle. DESIGN CONSTRAINTS The fllwing is a list f cnstraints set by the Shell Ec-Marathn Cmpetitin. The vehicle must cnfrm t these cnstraints, if nt the vehicle will nt be allwed int the cmpetitin. They are brken int several systems that the team is respnsible fr designing. Drive train Cnstraints (Transmissin & Clutch): Effective transmissin chain r belt guard(s): Prtect driver r technician Made f metal r cmpsite material Rigid enugh t withstand a break 5

6 Manual Clutch: Must nt have the starter mtr perable with the clutch engaged. Autmatic clutch: Mtr starting speed belw speed engagement f the clutch. Braking Cnstraints: 2 Independent Systems Frnt Wheel(s) Rear Wheel(s) All wheels must have braking frce applied Simultaneus Engagement Fuel System Cnstraints: Fuel must be Shell Regular Gasline (87) r E100 (100% Ethanl) Fuel tank must be APAVE certified and a vlume f either 30,100,r 250 cc Fuel tank must be munted in a zer degree psitin and at least 5cm belw the rll bar Air Intake must nt cntain any fuel r blwby gas Internal and external emergency shut-dwn systems must shutdwn the ignitin and fuel supply External system must be permanently munted t bdy External system must have a latching red push buttn and be labeled with a 10cm by 3cm wide red arrw n a white backgrund Fuel line between tank and engine may nt cntain any ther elements Fuel lines must be flexible and clear in clr and nt prne t expansin Teams cannt increase r decrease the fuel temperature Flat chambers must include a drain valve at the bttm f the carburetr t ensure fuel level ges dwn in the fuel tank 6

7 Electrical System Cnstraints: Maximum n-bard vltage must nt exceed 48V nminal Only ne n-bard battery and the battery must maintain a cnstant grund Electrical circuits must be prtected frm shrt circuit and verlad Electric hrn must be 85 dba and pitch f 429 Hz Electrical starter can nly perate when ignitin and fuel systems are activated Electrical starter must nt prvide prpulsin A red starter light must be installed n the rear f the vehicle with a luminescence f 21W and be clearly visible frm bth sides Starter and starter light must be extinguished by the time the rear wheel crsses the start line Technical Dcumentatin Cnstraints: Fuel System Full descriptin and detailed schematic frm tank t mtr Including pressurized air bttle, pressure relief valves, air pressure gauges, fuel tank, valves, injectrs, flat chambers, and pumps Descriptin f vehicle clutch peratin Specifically shwing starter mtr des nt engage clutch Electrical System Circuit diagrams with all cmpnents listing vltage, current, and pwer ratings Shw emergency stp switch lcatins fr inside and utside f car Shw battery lcatin with type and rated vltage Shw starter mtr lcatin All dcumentatin must be current, have printed cpies, and be displayed n a pster 7

8 PLANNING The prject has already begun with initial research. The prject is slated t end with the demnstratin f a high mileage vehicle in the SAE Ec-Marathn cmpetitin in Hustn, Texas. There are many steps in between the ends. A quick summary f thse items is: develping alternatives, chsing the best systems, wrking up full drawings, rdering/making parts, and fine tuning the system. It is pssible t make a mre granular breakdwn f the steps it is ging t take, hwever at this pint in develpment that is unnecessary due t the large amunt f unknwns still needing t be fleshed ut. A Gantt Chart is prvided in Appendix A with apprximate dates as t when different sectins f the prject that this team is respnsible fr are expected t start and cmplete. Quality Functin Develpment: Based n the QFD, as shw in Appendix B, it can be seen that weight is the mst relevant f the engineering requirements t satisfy the custmer needs. Therefre, the weight cmpnent f ur design has t be maximized the mst cmpare t the rest f the engineering requirements identified abve. It can als be seen that accessibility and steering gemetry are the least imprtant f ur engineering requirements which means they are nt relevant t ur client. As fr the rest f the engineering requirements, ur QFD shws that they are all f same imprtance which means we have t d ur calculatins carefully fr all f them as they will all be very imprtant t satisfy ur client. CONCLUSION: The Shell Ec-Marathn cmpetitin is designed t fster new ideas fr hw t imprve the efficiency f the mdern vehicle. The drive train sub-team fr the SAE Ec- Marathn NAU Capstne team is dedicated t creating the mst fuel efficient vehicle pssible within the cnstraints put frward by SAE and NAU. Fuel efficiency is f paramunt imprtance t every human being that drives a vehicle that runs n fssil fuels, nt nly because it s getting mre expensive, but because there isn t an infinite 8

9 amunt available t use fr fuel. This is a huge reasn that fuel efficiency needs t be cnstantly getting better. There have been a lt f advances in this area since the Ec- Marathn cmpetitin started 75 years ag as a bet between engineers, and hpefully in the next 75 years there will be expnentially mre prgress made t imprve fuel efficiency. REFERENCES Shell Ec-marathn, "Official Rules 2014 Chapter 1," cntent/dam/shell-new/lcal/crprate/ecmarathn/dwnlads/pdf/semglbal-fficial-rules-chapter pdf, 01 Oct "Surces." EPA. Envirnmental Prtectin Agency, n.d. Web. 03 Oct

10 APPENDIES Appendix A: Gantt Chart 10

11 Appendix B: QFD Chart 11