DEVELOPMENT OF COMPRESSED AIR POWERED ENGINE SYSTEM BASED ON SUBARU EA71 MODEL CHEN RUI

Transcription

1 DEVELOPMENT OF COMPRESSED AIR POWERED ENGINE SYSTEM BASED ON SUBARU EA71 MODEL CHEN RUI A project report submitted in partial fulfillment of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering Faculty of Mechanical Engineering UNIVERSITY MALAYSIA PAHANG JUNE 2013

2 ii UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the project entitled DEVELOPMENT OF COMPRESSED AIR POWERED ENGINE SYSTEM BASED ON SUBARU EA71 MODEL is written by CHEN RUI. I have examined the final copy of this report, and in my opinion, it is fully adequate in terms of language standard, and report formatting requirement for the award of the degree of Bachelor of Engineering. I herewith recommend that it be accepted in partial fulfillment of the requirements for the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Prof. Ir. Dr. Hassan Ibrahim Examiner Signature

3 iii SUPERVISOR S DECLARATION I hereby declare that I have checked this project, and in my opinion, this project is adequate in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Signature : Name of Main Supervisor : Gan Leong Ming Position : Senior Lecturer Date : Signature : Name of Co-Supervisor : Pr. Dr. Haji Rosli Bin Abu Baka Position : Professor Date :

4 iv STUDENT S DECLARATION I hereby declare that the work in this project is my own except for quotations and summaries which have been duly acknowledged. The project has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature : Name : Chen Rui ID Number : MH09095 Date :

5 ix TABLE OF CONTENTS Page EXAMINER S DECLARATION SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS ii iii iv vi vii viii ix xii xiii xv CHAPTER 1 INTRODUCTION 1.1 Background Study Problem Statement Objectives Scopes Hypothesis Flow Chart CHAPTER 2 LITERATURE REVIEW 2.1 Conventional Internal Combustion Engine Engine systems Working process of 4-stroke engine and 2-stroke 6 engine Flat four engine Fundamental of Compressed Air Engine Development of Compressed Air Engine 8

6 x 2.4 Compressed Air Technology (CAT) Construction of Compressed Air Engine Working Process of Compressed Air Engine Air Engine Cycle Governing Parameters & Equations Advantages & Shortages CHAPTER 3 METHODOLOGY 3.1 3D Reverse Engineering Engine overhaul & cleaning D drawing process Definition of Air Cycle Theoretical air cycle Prediction air cycle Design of Compressed Air Powered Engine Model Software Computation Analysis 28 CHAPTER 4 RESULT AND DISCUSSION 4.1 3D Reverse Engineering Air Powered Engine Design GT Power Computation Analysis 35 CHAPTER 5 CONCLUSION 5.1 Conclusion Recommendation 50 REFERENCES 51 APPENDICES A Gantt chart 52

7 xi B List of engine components after dismantling and cleaning 53 C List of engine components drawing in Solidworks 56 D List of plots in GT-Post 61

8 xii LIST OF TABLES Table No. Title Page 2.1 Technical Specification of CAT Vehicle Components of Compressed Air Engine Compressed Air Powered Compact CAFS (Truck Carried) Engine Geometry Engine MEP, Torque and Power Engine Operation Condition Engine Performance Predictions Key Cylinder Predictions Gas-Structure Heat Transfer 44

9 xiii LIST OF FIGURES Figure No. Title Page 2.1 A two-stroke free piston linear generator engine Flat-Four Engine Piston Position MDI Designed Air Engine Dwelling Connecting Rod Air Engine P-V Diagram P-V Diagram of Air Engine Cam Profile Measuring Theoretical Air Cycle P-V Diagram Air Powered Cylinder Theoretical Working Process Prediction Air Cycle P-V Diagram Air Powered Cylinder Prediction Working Process Piston and Cylinder Geometry of Reciprocating Engine Instantaneous Piston Speed Relative to Average Piston Speed as a Function of Crank Angle for Various R Values Force Position New Design of Camshaft New Design of Cylinder Head Design of Separation Port Templates for Air Engine in GT Power Setting of Intake Valve 37

10 xiv 4.6 Theta Array and Lift Array Indicated Power, Indicated Torque and IMEP Change Curve with Different Intake Valve Open Angle Valve Timing Graph Pressure and Temperature Curve in the Cylinder Fluid to Wall Heat Transfer Rate P-V Diagram 47

11 xv LIST OF SYMBOLS A B BP BMEP CR CTA EVO IVO IMEP K L m m n Cross-section area of piston Bore Brake power Brake mean efficiency pressure Cylinder compression ratio Cam timing angle Exhaust valve open angle Clearance height Intake valve open angle Indicated mean efficiency pressure Number of strokes Stroke length of piston Mass of gas Slope of P-V curve after TDC Amount of substance of gas Volumetric efficiency Volumetric efficiency from the table N N P P P Engine speed, rpm Crankshaft rotational speed Pressure of gas Power Instantaneous cylinder pressure between TDC and the transition point Brake power Pressure rise due to combustion Indicated power Pressure in upstream volume Intake pressure from the table Maximum cylinder pressure (pressure at TDC) Cylinder pressure at IVC

12 xvi R R S t T T T Pressure ratio (exh/int) across the cylinder Pressure ratio (exh/int) from the table Gas constant for a particular gas Ratio of the connecting rod length to crank offset Stroke Off-load time in minutes On-load time in minutes Temperature of gas Torque Temperature in upstream Intake temperature from the table Mean piston speed Indicated piston speed v V V V Specific volume Volume of gas Engine displacement Instantaneous cylinder volume between TDC and the transition point Piston cup volume Head region volume Cylinder volume at TDC Indicated work Shaft angular velocity Ratio of specific heat values for the intake air Specific heat ratio Mechanical efficiency Number of crank revolutions per cycle