EXPERIMENTAL VALIDATION OF AFTERMARKET FUEL SAVING DEVICE (VOLTAGE STABILIZER) NOOR AFFANDY BIN ABAS This thesis is present in partial fulfillment for the award of Degree of Bachelor of Engineering Mechanical (Automotive) Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka MAY 2010
I have read this thesis and from my opinion this thesis is sufficient in aspects of scope and quality for awarding Bachelor of Mechanical Engineering (Automotive) Signature :. Name of Supervisor : MR. NOREFFENDY BIN TAMALDIN Date :.
ii I admit that this report is on my own work except for summary and quotes that I have stated the source for each of them Signature :.. Name of Author : NOOR AFFANDY BIN ABAS Date : MAY 2010
Especially for beloved mom, dad, wife and family iii
iv ACKNOWLEDGEMENT I would like to express my greatest gratitude to ALLAH S.W.T for giving me strength and courage to complete this thesis. With HIS blessing and bestowed, I am able to complete this thesis on time. My special thanks go to my dedicated supervisor, Mr. Noreffendy bin Tamaldin who always provides good supervision, encouragement and critic. I am truly indebt with all the helps that he provide for me during completing this thesis. My thanks also go to my beloved my loving wife and family that support all through the process of completing this thesis. They have been a wonderful source of support, inspiration, and encouragement throughout my education, and they deserve much credit for where I am today. Lastly, to all persons that involve directly and indirectly with full willingness of contributing their efforts, time, energy and idea, helping me completed this thesis. There are not exact words that would able to express my feeling of gratitude toward them except thank you.
v ABSTRACT Aftermarket fuel saving devices (voltage stabilizer) manufacturer claim their product will reduce fuel consumption related to fuel economy and increase the engine performance. The functional of this product is to feed constant voltage current to electrical instruments and electronic devices and a combination of all these responses result in less fuel consumption and increase engine performance. This experimental validation has conducted by theory and experimental using one of aftermarket voltage stabilizer. The experimental validation has conducted with using Nissan Grand Livina 1.6L HR16DE 1.6 L with Automatic Transmission. The vehicle has tested before and after the installation voltage stabilizer with Dynomax 2000 Chassis Dynamometer for torque and power performance to determine its effects on fuel economy. The results indicated that the voltage stabilizer device has increase of torque performance about 1.4% begins at 2900 rpm and continuously to 6050 rpm. However, there is no significant effect for the purpose of fuel saving and reducing the cost of fuel consider the behavior of driver and limit speed of this country.
vi ABSTRAK Pengeluar produk eksesori penjimat minyak jenis penstabil voltan mengakui bahawa produk mereka dapat meningkatkan kuasa kecekapan pembakaran petrol dan menjimatkan kadar menggunakaan minyak serta secara tidak lansung meningkatkan prestasi injin. Ianya berfungsi dengan mengurangkan gangguan radas elektronik dengan menstabilkan arus elektrik agar semua kendalian peralatan elektronik ditahap yang optimum. Kajian secara teori dan ujikaji telah dilaksanakan terhadap salah satu alat penstabil voltan yang terdapat di pasaran dengan menggunakan alat penguji Dynamometer Kerangka ke atas sebuah kenderaan Grand Livina HR16DE 1.6 L. Hasil ujikaji mendapati terdapat sedikit peningkatan terhadap daya kilas injin selepas pemasangan alatan tersebut sebanyak 1.4 % iaitu bermula dari 2900 psm hingga 6050 psm. Namun demikian, tidak ada kesan penjimatan minyak dari aspek tabiat kebiasaan pemandu dan limitasi kelajuan kenderaan yang ditetapkan di negara ini.
vii TABLE OF CONTENTS CHAPTER CONTENTS PAGE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACK ABSTRAK TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES LIST OF GRAPHS ABBREVIATION ii iii iv v vi vii xi xii xiii xv
viii CHAPTER CONTENTS PAGE CHAPTER 1 INTRODUCTION 1 1.1 Overview 1 1.2 Aftermarket Voltage Fuel Saving Device 2 1.3 Problem Statement 4 1.4 Investigation of Aftermarket Voltage 5 Stabilizer Selection 1.5 Selection Investigation Apparatus 6 1.6 Objectives 7 1.7 Experimental Validation Scopes 7 CHAPTER 2 LITERATURE REVIEW 9 2.1 Overview 9 2.2 Vehicle Technology Related Factors 9 2.3 Human Driving Behavior Related Factors 13 2.4 Electrical Power System Related Factors 14 2.4.1 Basic electrical system 14 2.4.2 Voltage Regulator in Vehicle 16 Electrical System 2.5 Aftermarket Voltage Stabilizer 18
ix CHAPTER CONTENTS PAGE 2.5.1 VS4 Voltage Stabilizer 20 2.5.2 VS4 Voltage Stabilizer Features 21 2.5.3 VS4 Component Devices and 23 Function 2.5.4 VS4 Working Principle 24 2.6 Research Article 25 2.6.1 Research Article 1 25 2.6.2 Research Article 2 27 CHAPTER 3 EXPERIMENTAL METHODOLOGY 28 3.1 Introduction 28 3.2 Experimental Apparatus 30 3.2.1 The Vehicle 30 3.2.2 Max 2000 Chassis Dyno 33 3.3 Experimental Procedures and 31 Parameter 3.3.1 Max 2000 Chassis Dynamometer. 31 3.3.2 VS4 Voltage Stabilizer. 32 3.4 Mathematical Formulation 33 3.4.1 Engine Torque 33 3.4.2 Engine Power 33 3.4.3 Brake Specific Fuel Consumption 34
x CHAPTER CONTENTS PAGE CHAPTER 4 RESULTS AND ANALYSIS 36 4.1 Introduction 36 4.2 Experimental Result 36 4.2.1 Torque and Power without 37 VS4 4.2.2 Torque and Power with VS4 41 4.3 Analysis Torque and Power 45 4.4 Analysis Brake Specific Fuel 46 Consumption 4.5 Discussion 47 CHAPTER 5 CONCLUSION 48 5.1 Conclusion 48 5.2 Recommendation for Future Study 49 REFERENCES 50 BIBLIOGRAPHY 51 APPENDICES 53
xi LIST OF TABLES NO. TITLE PAGE 1.1 List Aftermarket Voltage Stabilizer 4 1.2 Nissan Livina Technical Data 6
xii LIST OF FIGURES NO. TITLE PAGE 1.1 Voltage Stabilizer Plug In Type 3 1.2 Voltage Stabilizer Battery Connector Type 3 1.3 Label of Sample Aftermarket Voltage Stabilizer Sampling 5 1.4 Experimental Validation Scope Chart 8 2.1 Energy Flow Rate for Medium Car 12 2.2 Car Electrical System 15 2.3 Lundell Alternator 15 2.4 Voltage Regulator 16 2.5 Claw Pole Alternators Circuit Diagram 17 2.6 Power Control Module Diagram 17 2.7 MOSFET Microcontroller Voltage Stabilizer 18
xiii NO. TITLE PAGE 2.8 Sample VS1 Electrical Component Devices 19 2.9 Sample VS2 Electrical Component Devices 19 2.10 Sample VS3 Electrical Component Devices 20 2.11 Cutaway View of VS4 Aftermarket Voltage Stabilizer 22 2.12 VS4 Voltage Stabilizer Circuit Diagram 24 2.13 The Measured of Voltage Drop 26 2.14 The Resistance Value of Connecting Grounding System 26 3.1 Experimental Methodology Chart 29 3.2 Chassis Dynamometer Setup 31 3.3 VS4 Voltage Stabilizer Installations 32
xiv LIST OF GRAPHS NO. TITLE PAGE 4.1 Engine Torque and HP vs. RPM (run 1 without VS4) 37 4.2 Engine Torque and HP vs. RPM (run 2 without VS4) 38 4.3 Engine Torque and HP vs. RPM (run 3 without VS4) 39 4.4 Torque and Power VS Engine Speed without VS4 (Average) 40 4.5 Vehicle Torque and HP vs. RPM (run 1 with VS4) 41 4.6 Vehicle Torque and HP vs. RPM (run 2 with VS4) 42 4.7 Vehicle Torque and HP vs. RPM (run 3 with VS4) 43 4.8 Torque and Power vs. Engine Speed with VS4 (Average) 44 4.9 Comparison Torque and Power vs. Engine Speed 45 4.10 Comparison BSFC vs. RPM 46 4.11 Comparison BSFC vs. Engine Speed and Engine Speed 47
xv ABBREVIATION AC = Alternating Current CDT = Cylinder Deactivation Technology CVT = Continuously Variable Transmission DAC = Data Acquisition Control DC = Direct Current DGEC = Dry Gap Water Cooled Eddy Current DRB = Diode Rectifier Bridge DOHC = Double Overhead Cam ECM = Engine Control Module EPA = Environmental Protection Agency LIVC = Late Intake Valve Closing IC = Integrated Circuit IRS = Interference Reducer System MOSFET = Metal Oxide Semiconductor Field Effect Transistor MPM = Mechanical Power Distribution MVICSA = Motor Vehicle Information and Cost Saving Act PAC = Power Acquisition Control PDM = Intelligent Power Distribution Module VVT = Variable Valve Timing Technology
1 CHAPTER 1 INTRODUCTION 1.1 Overview Fuel consumption is a very hot topic when fuel prices getting high and seems set to increase. The market has responded with a dozen of fuel saving device sold on the market that claims to improve the fuel economy and possibly improve engine performance of a vehicle. There are several different designs, but many are designed to fit on the air filter or fuel host or battery of a car and purportedly optimize torque and power performance in some way. Most "fuel saving devices" fit this pattern: a. About a 10-15% claimed fuel saving (gas saving / gas mileage improvement) b. Claimed reduced emissions c. Claimed improved performance Most aftermarket fuel saving device products not been tested and verify by SIRIM or government approved. There no agency in Malaysia like Environmental Protection Agency (EPA) in United Stated with enforcement under Section 511 of the Motor Vehicle Information and Cost Savings Act (MVICSA) mandatory the manufacturer to submit data to the EPA and apply for EPA testing through the Voluntary Aftermarket Retrofit Device Evaluation Program. Until now only one
2 aftermarket fuel saver device by Sabertec Company have pass following the rigorous EPA 511 Protocol, a test created to evaluate claims to reduce automobile exhaust emissions and improve fuel economy. Most possibility after installing the aftermarket device or changes vehicle s engine, emission system, fuel system, or electrical system have the potential to cause one or more problems like increased emissions, reduced fuel economy, harm vehicle condition, void the manufacturer warranty and environmental hazards. 1.2 Aftermarket Voltage Stabilizer Fuel Saving Device There are many aftermarket products that claim to improve economy and power via changes to the vehicle electrical system such as voltage stabilizer (VS) and grounding wires (to fit between the engine block and the vehicle body). It is true that vehicle electrical systems are inherently frequency noisy (due to ignition, alternator, etc), and by installing this add-on device could smooth this out. The electrical details of these devices are not specific and kept secret by the manufacturers. Most of voltage stabilizer manufacturer claims the benefits of their device such as: a. Better sound for in-car entertainment system. b. Smoother idle, especially when switch electrical devices on/off. c. Steadier light from headlamps; increased bulb life. d. Possibly sharp throttle response, especially from low engine revs and with a nearly flat battery. e. Possibly good starting although nearly battery flat. f. Increase battery life.
3 Commonly there are two various type voltage stabilizers for vehicle most popular among the customer depend on installation, price and warranty. First type voltage stabilizer is installation by plug in at cigarette lighter socket and the second type is installation by connection to battery terminal. The voltage stabilizer types are shown in Figure 1.1 and Figure 1.2. Voltage stabilizer can be finding in the market show in Table 1.1. Figure 1.1: Voltage Stabilizer Plug in Type Figure 1.2: Voltage Stabilizer Battery Connector Type
4 Table 1.1: List Aftermarket Voltage Stabilizer Name Product Type Price (RM) I-Change Plug In 595.00 E-Charge Plug In 580.00 Echo Charge Plug In 576.00 Echo Storm Plug In 380.00 Oricharge Plug In 400.00 Hot Enazma Eco Plug In 400.00 Power8 Plug In 480.00 Max Energy Plug In 50.00 Pivot Raizin Battery Connector 240.00 DIY Battery Connector 99.00 Max Speed Battery Connector 89.00 Zaptor Battery Connector 120.00 I-VS Battery Connector 129.00 1.3 Problem Statement From manufacturer advertisements, theirs similar claim that voltage stabilizer can decrease circuit noise and high frequency impedance for more stable voltage current to all electronic device. This will result in increase power, torque, improve fuel economy, and reduce emission and audio quality. For this research the aim is only to investigation the effectives of voltage stabilizer on the manufacturer claim of improving fuel economy and increase the engine performance. The effective of the voltage stabilizer will be validating after the experimental vehicle test with chassis dynamometer. The analyze data and results will approve or disapprove that the installation of voltage stabilizer will reduce the fuel consumption and increase torque and power.
5 1.4 Investigation of Aftermarket Voltage Stabilizer Selection For the purpose of this thesis, four samples of aftermarket voltage stabilizers are shown in Figure 1.3. Sample VS4 has been selected for this investigation because of transparent design and easy to dismantle for investigation purpose. This investigation will be conducted by theory and experimental for petrol engine. Research on theory will include the working principle of voltage stabilizer and an effective voltage stabilizer for the role of fuel saver and increase engine power and torque performance. Figure 1.3: Label of Sample Aftermarket Voltage Stabilizer Sampling
6 1.5 Selection Investigation Apparatus Selection of apparatus for this investigation only base on validation of increase engine power performance and reduce fuel consumption. The apparatus has been choosing as follow: a. Vehicle Grand Livina 1.6L engine HR16DE. Detail technical data shown in Table 1.2 b. Experimental Test Equipment Max 2000 Chassis Dynamometer. Table 1.2: Nissan Livina Technical Data (Source: Nissan Grand Livina User Manual) Nissan Grand Livina HR16DE 1.6 L Engine DOHC four cylinder Displacement 1,598 cc Bore X Stroke (78 x 83.6) mm Compression Ratio 9.8 : 1 Fuel System ECCS, Electronic fuel injections system Max power 77kW @ 5200rpm Max torque 150Nm @ 4,400rpm Fuel tank capacity 52 liter Weight 1245 kg
7 1.6 Objectives The objectives of this project are as follow: a. To investigate the functional and working principle of aftermarket voltage stabilizer. b. To investigate and validate the effectiveness of voltage stabilizer by experimental test using Chassis Dynamometer to manufacturer claim. 1.6 Experimental Validation Scopes Investigation methodology chart shown in Fig. 1.6 and explanation as follow: a. Literature study of working principle and functional voltage stabilizer related to increase torque and power performance and reduce fuel consumption. b. Literature study on present engine vehicle technology with related power performance and reduce fuel consumption. c. To identify suitable type of testing required for product validation. d. Analyze engine performance data result. e. Validation & reporting.
8 START Literature Study Experimental Methodology Dynochasis Test 1 Vehicle Without VS Dynochasis Test 2 Vehicle With VS Verify Results Satisfactory If No If Yes Analyze and Comparing Validation and Reporting End Figure 1.4: Experimental Validation Scope Chart