bhushan karayilthekkoot mae377 final

8/14/2019 Bhushan Karayilthekkoot MAE377 Final

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MAE 377

Final Project

Compressed Air Powered Engine

Bhushan Karayilthekkoot

12/14/2009


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ContentsContents ........................................................................................................................................................ 2

1 INTRODUCTION ..................................................................................................................................... 3

2 PROBLEM DEFINITION........................................................................................................................... 3

3 DESIGN GOALS ...................................................................................................................................... 3

4 Research on Similar Products ............................................................................................................... 4

4.1 Product survey .............................................................................................................................. 4

4.2 Pros and Cons ................................................................................................................................ 5

5 PROJECT MANAGEMENT....................................................................................................................... 6

6 ALTERNATIVE DESIGNS AND DESIGN SELECTION ................................................................................. 7

6.1 Sketches ........................................................................................................................................ 7

6.1.1 Design 1 ................................................................................................................................. 8

6.1.2 Design 2 ............................................................................................................................... 10

6.1.3 Design 3 ............................................................................................................................... 11

6.2 Design Selection: ......................................................................................................................... 12

7 DISCUSSION ......................................................................................................................................... 48

8 CONCLUSION ....................................................................................................................................... 49


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1 INTRODUCTIONIn todays date around 85% of the energy produced in USA has its source from some kind of

fossil fuel. We consume around 25% of the worlds crude oil with 5% of the worlds

population. A major part of this consumption is in forms of fuel (Gasoline or Diesel) for

engines running our cars, lawnmowers, trucks, moppets and all kinds of equipment in which

an engine can be used. The major problem with this is that the sources for these fuels are not

will run out and moreover the byproducts released while burning them create a number of

environmental and health problems for people all over the world. My product which is an

Engine that could run entirely on compressed air could be a tentative solution to all these

problems.

2 PROBLEM DEFINITIONThe purpose of this project is to develop a design for an engine which can tentatively run

completely on compressed air. The engine must be able to work without producing any

carbon footprint, must be cost effective and should be able to beat the competition in terms

of ingenuity and esthetics.

3 DESIGN GOALSThe engine should be able to work entirely on compressed air.The engine should work without any manual supervision

Should produce a displacement of at least 125cc.

A bare minimum of 5HP should be tentatively produced using the engine.

As small and light weight as possible


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4 Research on Similar Products4.1 Product surveyMy research on similar product has taken me to the following options:

Product

Name Pictures Features Cost

Hydrogen

Fuel Cell

Extremely environment friendly: produces

water vapor as a byproduct of internal

combustion.

High Energy Efficiency: A typical gas

powered engine uses around 20% of fuel to

power the vehicle while thi product can use

40%-60% of fuel to power the car.

Can produce up to 134 HP of power

Works on Hydrogen.

$3000-$4000

(Manufacturing

Cost)

Di Pietro

Engine

Outstanding Efficiency: up to 100% over gasengines.

Simple but extremely efficient design.

Low moving parts and virtually no friction andvibration.

Only 1Psi of pressure needed to overcome thefriction.

Works on Compressed Air.

N/A

Table 1: Product Survey


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4.2 Pros and ConsProduct names Pros Cons

Hydrogen Fuel Cell

Extremely Fuel Efficient.

Zero green house gasemission.

Can produce a goodamount of power.

Extremely expensive: boththe engine and the fuel.

Fuel not readily available

and expensive to produce.Winter risk: because itproduces water vapor asan emission the enginewill not produce sameefficiency in colderregions.

Di Pietro Enigine Almost 100% efficiency

compared to gasoline

powered engines.

Works entirely on thepressure from

compressed air.

Has virtually no friction

or vibration.

Still in Prototype Phase.

The exclusive research

could reflect in the form

of high cost whenlaunched.

Table 2: Pro & Cons of Competitive product.


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5 PROJECT MANAGEMENTTo manage this project and its technicalities I have created a Gantt chart to visualize how I will be going forward with it. I have

allocated specific timing for all the steps in the process of finishing this project before due date in the Gantt chart.

Table 3: Gantt Chart

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10

Project Proporsal 11/10/2009 11/13/2009 3

Phase 1 11/13/2009 11/17/2009 4

Gantt Chart 11/15/2009 11/17/2009 2

Research on Altertnative Products 11/13/2009 11/17/2009 4

Phase 2 11/13/2009 11/23/2009 10

Alternative Designs 11/13/2009 11/23/2009 10

Design Dec ision 11/19/2009 11/23/2009 4

Phase 3 11/23/2009 12/5/2009 12

3-D Modelling 11/23/2009 12/5/2009 12

2-D Drawings 12/3/2009 12/5/2009 2

User Manual 12/3/2009 12/5/2009 2

Final Phase 12/4/2009 12/10/2009 6

Power Point 12/8/2009 12/10/2009 2

Presention 12/7/2009 12/10/2009 3

Final Report 12/4/2009 12/9/2009 5Website 12/8/2009 12/10/2009 2

# of DaysObjective Start EndNovember December


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6 ALTERNATIVE DESIGNS AND DESIGN SELECTION

6.1 SketchesThe sketches below are my tentative designs for the engine. The first 2 have a piston cylinderdesign while the last one has a rotary engine design.


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6.1.1 Design 1

A


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6.1.2 Design 2

B

The second design works almost the same way as the first one except for the fact that it uses a

regular flat piston. Also this design includes a air compressor which can compress air back for

fueling the engine. The valves are controlled by the camshafts which in turn controlled by the

crankshaft. The valves here are to the side of the cylinder and the notch in the cylinder head

forces gases out of the cylinder.


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6.1.3 Design 3

C

Fig 1: A) Alternative Design #1; B) Alternative Design # 2; C) Alternative Design #3.

The third design is a conventional rotary fan design. When compressed air passes though the

blades it creates a torque. This torque rotates the crank shaft which can power the engine. But

due to the ample surface area I assume its efficiency will not be to par.


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6.2 Design Selection:

Alternative

Designs

Goals

TotalEfficiency

(25%)

Weight

(25%)

Eco-friendly

(10%)

Cost

(30%)

Aesthetics

(10%)

Design 1 20 20 10 20 8 78

Design 2 23 18 10 28 8 87

Design 3 10 24 10 25 8 77

From the above table I decided to design number 2.


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7 3-D CAD MODELSThe 3-D CAD Modeling involves using a CAD Software (Pro E) to create CAD Models of the

Engine. Every part of the product needs to created and then assembled. These parts we created

keeping in mind the basic sub assemblies which make up the important parts of the Engine, the

other parts which are not in the sub assembly are grouped together based on similarity in

working, shape, position or complexity.

7.1 ENGINE PISTON SUB-ASSEMBLYThis is the core of the design. The piston is flat and produces a 125cc displacement. It also is

connected to the reaction spring and reaction spring guide, which makes the exhaust phase

possible. The piston slides up and down this guide.

A


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B

C D


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E F

G H

I J


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K L

Fig 2: A) Piston Assembly; B) Piston Assembly Exploded; C) Piston Head; D) Piston Head in

different view; E) Piston Pin; F) Piston ring; G) Snap Ring; H) Piston Shaft; I) Bottom Part of

Piston Shaft; J) Shaft Bolt.

7.2 ENGINE VALVESThese valves control the intake and exhaust of the engine. The intake valve is a circular plug

which is place in the intake pipe and pivoted by the push rod while the exhaust valves are place

in the cylinder and are very similar to conventional engine valves. Both these valves have

individual camshafts to control them.

7.2.1 INTAKE VALVE


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A B

C D

Fig 3: A) Exhaust valve; B) Exhaust push rod; C) Exhaust Valve Spring; D) Exhaust valve pin.

7.2.2 EXHAUST VALVE

A B


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C D

Fig 3: A) Intake valve; B) Intake push rod(top); C) Intake push rod(bottom); D) intake valve

pin;.


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7.3 SHAFTSThis engine has 2 Camshafts and 2 Crankshafts which control the timing and creates the torque.

Out of these the engine has the main crankshaft and 2 camshafts for timing, while the air

compressor has the second crankshaft. The crank shaft in the engine controls the other 2

camshafts using gears. The gears were a very complex part to draw as it required a lot of

calculation to figure out the right size and teeth ratio. This ensures that the camshafts rotate at

half the speed of the crankshaft.

A B

C D


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E F

Fig 4: A) Exhaust camshaft; B) Exhaust camshaft in a different view; C) Intake Camshaft; D)

Intake Camshaft in a different view; E) Crankshaft; F) Air compressor crankshaft.

7.4 ENGINE HEADThis part consists of the cylinder head and the intake pipe. The intake pipe was a pretty easy part

to model but so was not the case with the cylinder head. The cylinder head was extremely

complicated and had to be modeled very carefully as it would guide how the cylinder of the

engine would look like. The cooling fins on the head gives the engine a realistic texture, although

for a compressed air powered engine with no exothermic reactions the fins need not be this long.

A B


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C

Fig 3: A) Cylinder Head; B) Cylinder Head in a different view; C) Intake Pipe.

7.5 ENGINE CYLINDERThis is most complex and important part of the entire design. It is extremely detailed and houses

the entire engine. It took a lot of tries to get this part right. The fins are made using pattern and

feature like boundary blend are also used here.

A


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B

C

Fig 4: A) Engine Cylinder; B) Engine Cylinder in a different view; C) Engine Cylinder from the

bottom.


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7.6 BELT PULLEY ASEMBLYThis assembly drives the air compressor. It is a simple assembly. It has 2 pulleys and a belt along

with the pulley keys. The only thing I had to take in to consideration was that to increase the

efficiency of the air-compressor the second pulley had to be half the size of the first one. Because

it is a belt pulley I have included trapezoidal patterns in the pulleys and belt to make it look

realistic.

A

B


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C D

E F


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G

Fig 5: A) Belt-Pulley Assembly Exploded; B) Belt-Pulley Assembly; C) Smaller Pulley; D)

Bigger Pulley; E) Bigger Key; F) Smaller Key; G) Belt.

7.7 AIR-COMPRESSOR CYLINDERThis part was fairly simple compared to the engine cylinder. But due to the exquisite details on it

I have identified it separately.

A

Fig 3: A) Air Compressor Cylinder.


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7.8 AIRCOMPRESSOR PISTON ASSEMBLYThis assembly is exactly similar to the engine piston assembly except for the lack of the guide

and spring. The piston here is smaller in size but displaces almost the same amount of air. Also

there is only one piston ring in this assembly; this is to increase the efficiency of the compressor.

Also the size of the ring is larger here compared to the engine.

A

B


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C D

E F

G H


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I J

Fig 6: A) Piston Assembly; B) Piston Assembly Exploded; C) Piston Head; D) Piston Head in

different view; E) Piston Pin; F) Piston ring; G) Snap Ring; H) Shaft Bolt; I) Piston Shaft;

J) Bottom Part of Piston Shaft;.


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7.9 AIR-COMPRESSOR HEADThis design is probably the most conceptual one in this assembly. The air-compressor head

accommodates two one way valves facing in opposite directions functioning as intake and

exhaust.

A


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B

C


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D E

F G


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H I

Fig 7: A) Air Compressor Head Exploded; B) Air Compressor Head Showing Inner mechanism;

C) Air Compressor Head assembly; D) Air Compressor Head; E) Compressor head in different

view; F) Rivet; G) Valve; H) Valve base; I) Valve spring.


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8 ASSEMBLYThe assembly was easy enough with all the subassemblies sorted out. Rendered pictured of the

assembly and its special feature are highlighted below.

A

B


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C

D


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E

F


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G

Fig 8: A) ,B), D) Rendered pictures of engine in different views; D), E) , F), G)Rendered picture

of engine showing internal mechanism.


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9 2-D Technical drawings9.1 BOM

A

Fig 9: Bill of Materials for the Compressed Air Powered Engine.


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9.2 Sub-Assemblies9.2.1 Engine Piston Assembly

A

Fig 9: A) 2-D Drawing of Engine-Piston assembly.


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9.2.2 Engine Valves

A

Fig 10: A) 2-D Drawing of Engine valves.


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9.2.3 Shafts

A

Fig 11: A) 2-D Drawing of Shafts.


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9.2.4 Engine Head

A

Fig 12: A) 2-D Drawing of Engine Head.


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9.2.5 Engine Cylinder

A

Fig 13: A) 2-D Drawing of Engine Cylinder.


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9.2.6 Belt-Pulley Assembly

A

Fig 14: A) 2-D Drawing of Belt-Pulley assembly.


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9.2.7 Air -Compressor Cylinder

A

Fig 15: A) 2-D Drawing of Air-compressor Cylinder.


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9.2.8 Air-Compressor Piston Assembly

A

Fig 16: A) 2-D Drawing of Air-Compressor Cylinder assembly.


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9.2.9 Air-Compressor Head

A

Fig 17: A) 2-D Drawing of Air-Compressor Head assembly.


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10AnimationThe Animation shows all the parts flying away to demonstrate all the parts in this assembly. The

Working although turned out to be more difficult than I imagined it to be. Because of lack of

time to figure it out I decided to skip the working of the engine in the animation. I have a

rendered and non-rendered animation in which the rendered animation shows various materials

used in the engine with exquisite detail.

A


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B

Fig 18: A) Rendered Animation; B) Non-Rendered Animation

11DISCUSSIONThis proposal was pretty much brain storming and this is usually the fun part. This is where we

get to use our imagination and come up with stuff which will intrigue people and you never

know if you just stumbled on to a new invention. The animation for Design turned out to be

extremely difficult. With over 46 parts the creating a exploded view in animation was pretty

difficult, but


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12CONCLUSIONThe project was the most brain racking one I have done till date. It forced me to think in the

way a real world engineer would think. It is not only about creating a product learning how

to present it in a professional way so that it could reach the masses. The chances of this

engine to work in a real life are slim without proper R&D data. Also there might be various

structural flaws in this design as the materials I have used and the shape and size of in which

they are used could be inaccurate. Even if there is no structural flaw the efficiency this

engine would give is questionable. But maybe with enough research such an engine could be

manufactured in real.

13ReferencesSham Tickoo, Totorial1, in Pro/Engineer Wildfire for Designers, CADCIMTechnologies, 2003.

http://macmastercar.com

bhushan karayilthekkoot mae377 final

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