Showing posts with label mechanical projects. Show all posts
Showing posts with label mechanical projects. Show all posts

Sunday, 13 September 2015

Fuel Efficiency in All Wheel Drive (AWD) System

Introduction


        What people look for when buying a car? Many things, we do a lot of research before making such an investment. And one of the major features we look into is its fuel efficiency. The race to produce the most fuel efficient engine is now going on in India. Each month car companies are proving that this race will go on for a while (The last car released Honda Jazz has an FE of 27 km/litre for its diesel model, this was unthinkable a few years ago.
         We, mechanical engineers, know that a 2 WD vehicle is more fuel efficient than a 4WD one. Though the car companies in India except Mahindra & Toyota (for SUVs) are not coming with any 4 WD vehicles now, it could be the next trend in Indian automobile industry.
           This final year mechanical project is about creating a software simulation system to find out the power losses in the propeller shafts of All Wheel Drive (AWD) vehicles. The simulation program developed is called ‘Propeller Shaft Calculator’. This calculator is not an actual computer program but rather a ‘MS Excel’ program which contains rows and columns where you can input different dimensions and it calculates and outputs the apt dimensions for the new energy efficient propeller shaft.
           In this project different components of an AWD system is studied closely to see if there are any potential ways to reduce power loss. The components for the study involves propeller shaft, joints and bearings of the AWD system. The aim of this project is to create a simple tool that will help in the making of a better fuel efficient propeller shaft.

The aims of this project include:
• Obtain deeper knowledge about the chosen parts on the propeller shaft to find the greatest causes to power losses and to give proposals how these can be reduced.

• Write a report with facts about the propeller shaft and its components that can be used as a support while designing an efficient driveline.

• Create a program that calculates the different angles and directions between the parts on the propeller shaft after inserted specific data.

• Create a model for calculating the natural frequency of the propeller shaft.

• Get to know engineers within the Automotive industry.

• Learn how a modern AWD-system works.

• Increase the knowledge about the car manufacturing industry.

Last but not the least, this program doesn’t calculate the power losses on different joints of the propeller shaft.

Reference video : https://youtu.be/HJiH3eYfelM

Friday, 11 September 2015

Four Stroke Cycle Engines

Introduction

              A four-stroke cycle engine is an internal combustion engine that utilizes four distinct piston strokes (intake, compression, power, and exhaust) to complete one operating cycle. The piston make two complete passes in the cylinder to complete one operating cycle. An operating cycle requires two revolutions (720°) of the crankshaft. The four-stroke cycle engine is the most common type of small engine. A four-stroke cycle engine completes five Strokes in one operating cycle, including intake, compression, ignition, power, and exhaust Strokes.





Intake Stroke

         The intake event is when the air-fuel mixture is introduced to fill the combustion chamber. The intake event occurs when the piston moves from TDC (top dead center) to BDC (bottom dead center) and the intake valve is open. The movement of the piston toward BDC creates a low pressure in the cylinder. Ambient atmospheric pressure forces the air-fuel mixture through the open intake valve into the cylinder to fill the low pressure area created by the piston movement. The cylinder continues to fill slightly past BDC as the air-fuel mixture continues to flow by its own inertia while the piston begins to change direction. The intake valve remains open a few degrees of crankshaft rotation after BDC. Depending on engine design. The intake valve then closes and the air-fuel mixture is sealed inside the cylinder.



        The compression stroke is when the trapped air-fuel mixture is compressed inside the cylinder. The combustion chamber is sealed to form the charge. The charge is the volume of compressed air-fuel mixture trapped inside the combustion chamber ready for ignition. Compressing the air-fuel mixture allows more energy to be released when the charge is ignited. Intake and exhaust valves must be closed to ensure that the cylinder is sealed to provide compression. Compression is the process of reducing or squeezing a charge from a large volume to a smaller volume in the combustion chamber. The flywheel helps to maintain the momentum necessary to compress the charge.
When the piston of an engine compresses the charge, an increase in compressive force supplied by work being done by the piston causes heat to be generated. The compression and heating of the air-fuel vapor in the charge results in an increase in charge temperature and an increase in fuel vaporization. The increase in charge temperature occurs uniformly throughout the combustion chamber to produce faster combustion (fuel oxidation) after ignition.
           The increase in fuel vaporization occurs as small droplets of fuel become vaporized more completely from the heat generated. The increased droplet surface area exposed to the ignition flame allows more complete burning of the charge in the combustion chamber. Only gasoline vapor ignites. An increase in droplet surface area allows gasoline to release more vapor rather than remaining a liquid.
          The more the charge vapor molecules are compressed, the more energy obtained from the combustion process. The energy needed to compress the charge is substantially less than the gain in force produced during the combustion process. For example, in a typical small engine, energy required to compress the charge is only one-fourth the amount of energy produced during combustion.
          The compression ratio of an engine is a comparison of the volume of the combustion chamber with the piston at BDC to the volume of the combustion chamber with the piston at TDC. This area, combined with the design and style of combustion chamber, determines the compression ratio. Gasoline engines commonly have a compression ratio ranging from 6:1 - 10:1. The higher the compression ratio, the more fuel-efficient the engine. A higher compression ratio normally provides a substantial gain in combustion pressure or force on the piston. However, higher compression ratios increase operator effort required to start the engine. Some small engines feature a system to relieve pressure during the compression stroke to reduce operator effort required when starting the engine.


Ignition Event 

         The ignition (combustion) event occurs when the charge is ignited and rapidly oxidized through a chemical reaction to release heat energy. Combustion is the rapid, oxidizing chemical reaction in which a fuel chemically combines with oxygen in the atmosphere and releases energy in the form of heat.
       Proper combustion involves a short but finite time to spread a flame throughout the combustion chamber. The spark at the spark plug initiates combustion at approximately 20° of crankshaft rotation before TDC (BTDC). The atmospheric oxygen and fuel vapor are consumed by a progressing flame front. A flame front is the boundary wall that separates the charge from the combustion by-products. The flame front progresses across the combustion chamber until the entire charge has burned.


Power Stroke

         The power stroke is an engine operation Stroke in which hot expanding gases force the piston head away from the cylinder head. Piston force and subsequent motion are transferred through the connecting rod to apply torque to the crankshaft. The torque applied initiates crankshaft rotation. The amount of torque produced is determined by the pressure on the piston, the size of the piston, and the throw of the engine. During the power Stroke, both valves are closed.


Exhaust Stroke

       The exhaust stroke occurs when spent gases are expelled from the combustion chamber and released to the atmosphere. The exhaust stroke is the final stroke and occurs when the exhaust valve is open and the intake valve is closed. Piston movement evacuates exhaust gases to the atmosphere.
As the piston reaches BDC during the power stroke combustion is complete and the cylinder is filled with exhaust gases. The exhaust valve opens, and inertia of the flywheel and other moving parts push the piston back to TDC, forcing the exhaust gases out through the open exhaust valve. At the end of the exhaust stroke, the piston is at TDC and one operating cycle has been completed.


Uses in : Bikes, cars, buses, trucks

Reference video : https://youtu.be/OGj8OneMjek 

Anti-Lock Braking System (ABS)

Introduction

                  The ABS (Anti-lock Brake System) monitors the speed of each wheel to detect locking. When it detects sudden braking, it will release braking pressure for a moment and then provide optimum braking pressure to each wheel. By repeating this process in a short period of time, it enhances steering control during sudden stops. As a result, it will also help improve the ability of stopping the vehicle.



                   The role of the ABS is to control the wheel speed in order to prevent the wheels from locking and to assure a maximum braking force. This is of major importance when the runway is slippery or very short. Wheel moment of inertia, Rotational wheel speed, Friction coefficient, Wheel Radius Normal force per wheel Friction force, Aircraft speed are analogous to the above vehicle wheel shown. Forces acting on a braked wheel .The ABS commands the brake pressure as a function of the difference between the measured and the reference wheel speed.

                   The latter is calculated from the measured aircraft speed and the desired wheel slips, using equation. At the moment, when the pilot pushes the brake pedal the brake pressure and the wheel slip increase provoking a ground force between tyre and runway. Assuming the case of full braking, the ABS will control the wheel speed to its reference value. To achieve a maximum braking force the reference slip should be chosen close to the optimum slip. However, when the pressure level in the brakes becomes too high, the wheel slip slides beyond the optimum of the adhesion curve and the system tyre/runway becomes instable. The slope of u (s) being negative, the wheel immediately starts to lock. In this case, the ABS rapidly releases the brake pressure to force the wheel speed back to the stable side of the adhesion curve. In fact, this situation occurs, when either the desired slip s, has been chosen on the instable side of the friction characteristic, or when a sudden change in ground force is encountered (e.g. a transition from a dry to a wet runway surface). The principle problem in ABS design is that the optimum slip and the exact shape of the adhesion characteristic depend on the runway surface and further parameters, which cannot be measured, such as the condition of the tyres or the dynamics of the normal forces. Bearing in mind that the optimum slip value may vary between 3% and 20%, it is clear that the choice of the reference slip value is crucial for a safe and efficient ABS. If it is too small the braking force might become insufficient, if it is too high, wheel lockup occurs.

                 Recently there has been a growing interest in intelligent control techniques for the design of aircraft and road vehicle Antilock Brake Systems (ABS). In particular, rule-based, fuzzy logic controllers have been applied to this problem and successfully tested in simulation. In fact, the use of non-linear, fuzzy control techniques appears to be particularly appropriate for the ABS control problem because of the high non-linearity of the system and the lack of a precise physical model of the friction force between tyre and runway. In addition to that, the controller must operate at an unstable equilibrium point to achieve an optimal braking performance. The most important problem in ABS control design - fuzzy or conventional - is that the optimum adhesion coefficient varies significantly with the surface condition (i.e. dry, wet, icy, etc.) of the runway. Because the latter is unknown, it is extremely difficult to define a controller that guaranties an optimal braking performance for all types of runway conditions.

How Do Wheels Lock?


            During braking, wheels lock if the brake force applied is more than the friction between the road and tyre. This often happens in a panic braking situation, especially on a slippery road. When the front wheels lock, the vehicle slides in direction of motion. When the rear wheels locks, the vehicle swings around. It is impossible to steer around an obstacle with wheels locked. Locked wheels can thus result in accident. Skidding also reduce tyre life.





What Does ABS Do?


             The system detects when the wheel are about to lock and momentarily release the pressure on locking wheel. The brakes are reapplied as soon as the wheels have recovered.


        A toothed wheel (pole wheel) is fitted to the rotating wheel hub. A magnetic sensor mounted on each wheel in close in close proximity to the teeth, generates electrical pulses when the pole wheel rotates. The rate at which the pulses are generated (frequency) is a measure of wheel speed. This signal is read by electronic control unit (ECU). When a wheel is lock, the ECU (electronic control unit) sends an electrical signal to the modulator valve solenoid, which release pressure from the brake chamber. When the wheel recovers sufficiently, the brake pressure is reapplied again by the switch off signal to the modulator valve.



         The modulator valve has an addition ‘hold’ state which maintains pressure. In break in the chamber, thus optimizing the braking process. The cycling of modulator valve (5 to 6 times per second) is continued till the vehicle comes to a controlled stop. With ABS, the vehicle remains completely stable even when the driver continues to press the brake pedal during braking, thus avoiding accidents.






Uses in : Apache RTR , Swift Dzire, BMW

Reference video : https://youtu.be/mKiTAcXK6M4
                          https://youtu.be/12r0wUBhMF4
                                    https://youtu.be/t1JRRywzXPc