Small Engine Emissions Reduction Project Number 06109 Sponsor: Stone Construction Equipment, Inc. Team Members: Celeste Luce (Team Leader – Mechanical Engineer) Benjamin Heiser (Mechanical Engineer) Mark Siemer.
Download ReportTranscript Small Engine Emissions Reduction Project Number 06109 Sponsor: Stone Construction Equipment, Inc. Team Members: Celeste Luce (Team Leader – Mechanical Engineer) Benjamin Heiser (Mechanical Engineer) Mark Siemer.
Small Engine Emissions Reduction Project Number 06109 Sponsor: Stone Construction Equipment, Inc. Team Members: Celeste Luce (Team Leader – Mechanical Engineer) Benjamin Heiser (Mechanical Engineer) Mark Siemer (Mechanical Engineer) Brent Smith (Mechanical Engineer) Coordinator: Dr. Alan Nye Mentor: Dr. Ali Ogut Project Overview Stone Construction Equipment The Mud Buggy Emissions Mission Statement Develop a new design or modification that provides a cost effective solution to reducing emissions on the Mud Buggy. The desire is to be able to use the equipment manufactured by Stone Construction within unfinished buildings, without risk to individuals using the equipment. This design must comply with EPA regulations, and if used in an confined environment, meet OSHA standards. Design Process Needs and Objectives Brainstorm and Develop Concepts Feasibility Assessment Best Concept Engineering Analysis and Complete Design Needs and Design Specifications Develop an engineering model which: Lowers emissions Maintains EPA certification Is low cost Is aesthetically pleasing and marketable Is able to fit through an unfinished door Fits inside current plastic housing Is consistent with current power and safety features Does not void original engine manufacturers warranty Performance Specifications Engine must have 13 HP Comparable fuel usage Must be able to push the hydraulic pump over relief without stalling (2900 psi) Must be able to keep a consistent flow rate of fluid out of the hydraulic pump Emissions Regulations Environmental Protection Agency California Air Resources Board All engines sold must be EPA certified All engines sold in California must be CARB certified Occupational Safety and Health Administration Concept Development Electric Power Catalyst Alternative Fuels Propane Biodiesel Forge Technology Partnerships Electric Power Near zero emissions Requires use of batteries and/or generators Multiple motor control options High energy efficiency No market at this time Manufacturing Catalyst Made up of two parts Housing Substrate Honeycomb coated with the metallic catalyst Replaces existing muffler Can be EPA certified as separate unit Catalyst – DCL International Inc. Exhaust gases enter the catalyst and react with the substrate resulting in the creation of water and carbon dioxide. This results in a decrease of carbon monoxide, hydrocarbons, and particulates Propane Engines Available Honda GXV390 LPG Kohler CH14 LPG 13 Horsepower Vertical shaft orientation 14 Horsepower Horizontal shaft orientation Briggs and Stratton 480cc V-Twin New Development 16 Horsepower Horizontal shaft orientation Propane Mounting Options Honda GXV390 Vertical position Gears Horizontal mounting 90 degree gear box Belt/Chain Kohler CH14 Maintains current configuration Current configuration of the Mud Buggy Vertical Mounting Does not fit inside cowl Custom adapter Honda Propane Vertical Configuration Engineering Model Cost: Honda Propane Vertical Shaft Engine: $521 Regulator Kit: list price $300 Propane Tank: $151 Custom Adapter: $20 Engine/Pump Stand: $30 Additional parts and manufacturing needed: $200 CO testing equipment and other safety requirements: $800 Rough Estimated Total: Approximately $2001 Running the Hydraulic Pump with a Belt or Chain Energy Lost Overhung Load Adapter Size Constraints Honda Propane Vertical Configuration Engineering Model Cost: Honda Propane Vertical Shaft Engine: $521 Regulator Kit: list price $300 Propane Tank: $151 Sprockets or Pulleys (custom + common): $50 Overhung Load Adapter for Hydraulic Pump: $700 Belt or Chain: $12 Engine/Pump Stand: $30 Additional parts and manufacturing needed: $200 CO testing equipment and other safety requirements: $800 Rough Estimated Total: Approximately $2651 1st Horizontal Shaft Propane Solution Kohler CH14 LPG Advantages Engine includes two-stage regulator No frame modifications Use existing adapter 12 Volt electric system Significantly lower emissions No additional calibration necessary Disadvantages Less horsepower and torque Cost of engine Kohler CH14 Directly bolts to existing adapter Exhaust opposite side Engineering Model Design Bill of Materials Cost Comparison Cost of new components: Cost of components no longer needed: Cost added to the unit: $2207.55 - $ 527.39 $1680.16 Emissions Analysis HC + NOx 450 400 350 300 250 200 150 100 50 0 Emission Levels (g/kW-hr) CO Levels (g/kW-hr) CO Levels Honda GX390 Kohler CH14 Briggs and Honda GXV390 Stratton 480cc Engine 10 9 8 7 6 5 4 3 2 1 0 Kohler CH14 Briggs and Stratton 480cc Engine Honda GXV390 Closed Loop System Propane Air Metering Valve Carb Intake Manifold Engine Control Unit Engine Oxygen (O2) Sensor Exhaust Catalyst ExhaustH2O CO2 N2 Engine Performance Analysis Theoretical Torque Theoretical Power 25 20 18 16 Honda GX390 Gas Kohler CH14 Propane Briggs & Stratton V-Twin 20 Torque (ft*lb) Power (hp) 14 12 10 8 15 10 6 4 Honda GX390 Gas Kohler CH14 Propane Briggs & Stratton V-Twin 5 2 0 2000 0 2200 2400 2600 2800 RPM 3000 3200 3400 3600 2000 2200 2400 2600 2800 RPM 3000 3200 3400 3600 Propane Tank Selection “Fork Lift” style 20lb tank due to size constraints Engine Amount/Type of Fuel Endurance Honda GX390 7 gallons Gasoline 6 hours Kohler CH14 20lb propane tank 4 hours Testing Stall Test Dump Speed Test Travel Speed Test Flow Rate Test Noise Test 2nd Horizontal Shaft Propane Solution Briggs & Stratton V-Twin $678.46 Requires regulator & fuel lock-off Requires CO tester and additional calibration To be investigated further Plan for Senior Design II Overview of Schedule - Senior Design II Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Horizontal LPG Solutions Receiving parts Build Test Analysis Final Paperwork Poster Technical Paper Presentation Website Questions? House Of Quality Analysis