“Internal Combustion Engine” Final Design Report Instructor: John Fabijanic Sponsor: Joseph Mello Mechanical Engineering Department California Polytechnic State University San Luis Obispo Jason Wu Paing Htet Lin [email protected] [email protected] Philippe Daniel Habets Ricardo Cuevas [email protected] [email protected] Sam S. Flood [email protected] Executive Summary ............................................................................................................... 7 TableIntroduction of Contents .......................................................................................................................... 7 Competition ...................................................................................................................................8 Existing Designs ..............................................................................................................................9 Competition Winners ............................................................................................................................................ 9 Previous Cal Poly Engines...................................................................................................................................... 9 Technology Research ......................................................................................................................9 Intake and Exhaust ................................................................................................................................................ 9 Thermodynamics ................................................................................................................................................ 11 Compression Ratio .............................................................................................................................................. 15 Bore to Stroke Ratio ............................................................................................................................................ 16 Air Starting Systems ............................................................................................................................................ 17 Customers ........................................................................................................................... 18 Summary of Meetings/Interviews ................................................................................................. 18 Dr. Mello Interview – April 11th, 2019 ................................................................................................................. 18 Will Sirski Interviews ........................................................................................................................................... 18 Dr. Lemieux Interview – April 24th, 2019 ............................................................................................................ 19 Objective ............................................................................................................................. 19 Problem Statement ...................................................................................................................... 19 Customer Needs ........................................................................................................................... 19 QFD ............................................................................................................................................. 20 Final Product Specifications .......................................................................................................... 21 Concept Generation ..................................................................................................................... 22 Concept Evaluation ...................................................................................................................... 24 Thermal Management Structure Evaluation ...................................................................................................... 25 Insulation Material Evaluation ............................................................................................................................ 26 Intake/Exhaust Evaluation .................................................................................................................................. 28 Electric Starting System ...................................................................................................................................... 31 Preliminary Concept Design .......................................................................................................... 32 Thermal Management ........................................................................................................................................ 33 Intake and Exhaust .............................................................................................................................................. 35 Compression Ratio .............................................................................................................................................. 36 Electric Starting System ...................................................................................................................................... 37 Final Design ......................................................................................................................... 38 Post-CDR Change Summary .......................................................................................................... 39 Thermal Management System ............................................................................................................................ 39 Intake and Exhaust .............................................................................................................................................. 39 Dynamometer Fixture ......................................................................................................................................... 39 Electric Starting System ...................................................................................................................................... 39 Electronic Fuel Injection ...................................................................................................................................... 40 i Thermal Management System ...................................................................................................... 40 Intake and Exhaust ....................................................................................................................... 42 Resonator ............................................................................................................................................................ 42 Exhaust ................................................................................................................................................................ 43 Lotus Engine Simulation ...................................................................................................................................... 44 Safety and Maintenance ..................................................................................................................................... 46 Manufacturing Plan ............................................................................................................................................ 47 Design Verification Plan ...................................................................................................................................... 47 Bill of Materials ................................................................................................................................................... 48 Dynamometer Fixture .................................................................................................................. 49 Reduction Power Train ....................................................................................................................................... 49 Engine Mount ..................................................................................................................................................... 55 Safety and Maintenance ..................................................................................................................................... 56 Manufacturing Plan & Report ............................................................................................................................. 57 Design Verification Plan & Report ...................................................................................................................... 60 Bill of Materials and Cost Summary .................................................................................................................... 61 Electric Starting System ................................................................................................................ 62 Motor .................................................................................................................................................................. 62 Clutch & Reduction Systems ............................................................................................................................... 64 Mounting Bracket ..............................................................................................................................................