The Challenge

Through an academic partnership called PACE, General Motors challenged us to design a low-cost, fuel-efficient vehicle for developing countries.

Our sponsor, Belcan Engineering, Inc. provided funding, engineering support, and critical feedback throughout the project.

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http://www.businessweek.com/autos/autobeat/archives/GM%2520Logo.jpghttp://www.belcan.com/companyinfo.php

How do you design a car for better gas mileage?

Reduce weight…

…reduce drag…

…reduce rolling resistance…

…use a more efficient power source…

…capture waste energy…

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Emerging Markets

In 2008, 64 percent of GM’s sales occurred outside the United States, up from 59 percent the previous year.

http://www.nytimes.com/2009/01/22/business/22auto.html 4

Emerging Market VehicleConsumers in emerging markets• …value their hard-earned money.• …appreciate quality.• …are first-generation “middle class.”• …are getting tired of pollution.

They want a vehicle that• …is economical• …is reliable.• …is comfortable and convenient.• …is environmentally responsible.

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PACE Emerging Market Vehicle SpecificationsBy July 2011, design and manufacture a vehicle which: Sells for under $8,000 U.S. Dollars (2008) Has excellent fuel economy (60 mpg) Fully loaded weighs under 2,921 lb (1,325 kg ) Cruises at 75 mph (120 km/h) on grades up to 3% Is able to climb a 20% grade Accelerates from 0-60 mph in 16 seconds Has a driving range of 400 km (250 miles) Meets Euro 5 (future) emissions standards

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EMV Project SchoolsSchool Vehicle System(s)

University of Sao Paulo Project Management, Safety, Body Structure, Interior Design

Brigham Young University Fuel Powerplant, Exhaust and EmissionsUniversity of Puerto Rico Electric Powerplant,

University of British Columbia Hybrid Powerplant

Prairie View A&M University Transmission and Clutch

McMaster University Fuel Systems

Northwestern University Electric and Control Systems

RWTH Aachen Auxiliary Devices

PES Institute of Technology HVAC

홍익대학교 (Hongik University) Body CFD, Full Vehicle Dynamics

University of Cincinnati Suspension

Sri Jayachamarajendra College of Engineering

Brakes

University of Texas at El Paso Steering

University of Ontario Institute of Technology Body Design

성균관대학교 (Sungkyunkwan University) Design for Manufacturing7

Project Objective

By March 25th 2009, define and build an engine prototype that produces 66 ft-lb. of torque and 65 hp brake power and achieves 60 miles per gallon (gasoline equivalent ) fuel economy.

By July 20th 2009, validate the prototype’s performance through testing. 

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The Competition

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Price (USD)

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Power (HP)

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Passenger Capacity

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Fuel Economy (MPG)

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1. Diesel/Bio Diesel

2. Compressed Air Pressure

Engine

4. Compressed Natural Gas /

Gasoline

5. Multi-fuel Ethanol/Gasol

ine + LNG

17. Variable Compression Ratio,

movable compression chamber top

16. Oil-actuated

movable cams

15. Pancake griddle on exhaust manifold

14. Direct Injection

Spark Ignition

13. High Pressure Boost Natural Gas at

Home

12. Turbocharger

and steam boiler

9. Hydrogen Internal

Combustion

8. Gasoline/ Natural Gas

Flex

7. Natural Gas

45. Low-friction

cylinder liner

34. Regenerative braking – compressed

air

33. Regenerative braking – compresses air, engine as

compressor

32. Cyclonic air filter to reduce intake pressure

31. Parallel combustion – electric drive

30. Series combustion – electric drive

29. Steam engine

28. Steam turbine using exhaust

waste heat

27. Mechanical variable cylinder shutoff (clutch

mechanism)

26. Fly wheel energy storage

25. Plug-in electric only

23. Miller cycle valve

train

22. Heat transfer cylinder

wall coating

20. Ball valve tappet

19. Rotary valve train

18. Actively-tuned

exhaust

42. Cylinder shutoff

40. Variable valve timing, timing chain

39. Variable valve timing,

electric

37. Liquid nitrogen power

36. Ignition control (No

throttle plate)

35. Reduce exhaust pressure when

braking21. Coated rotary cams

with adjustable timing

11. Adjust cam for throttle

10. Gasoline engine

6. Gasoline & Ethanol

(separate tanks)

3. Gasoline & Ethanol “flex”

47. Regenerative braking –

compressed air

43. Compressed air – fill at home

44. Regenerative

braking - flywheel

41. Regenerative braking – rubber

band

38. Variable intake

pressure

24. Alka-Seltzer engine

48. 6-cycle, air assist

Integrated Starter

Turbocharger

Direct Injection

Variable Cylinder Shutoff

Heat Transfer Liner

Low-friction Wall Liner

Regular Unleaded Gasoline

“Flex” Gasoline / Ethanol

Diesel

Compressed Natural Gas

Direct Injection, Spark Ignition

Small Gasoline / Ethanol Engine

Turbocharger

Mechanical Concepts

Fuel Concepts

ConceptGeneration

Screening &

Scoring

Prototyping System Concept

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Power System Concept• Small engine (500-800 cc)• Turbocharger to increase power output• Direct injection to improve fuel efficiency• Gasoline / Ethanol for global fuel flexibility

+ +

Small Engine

Turbocharger Direct Injection

+Gasoline

orEthanol

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2008-2009 Prototype• BMW Motorcycle Engine (Rotax 654cc 1-cyl.)• Aerocharger Variable-Geometry Turbocharger• Use high octane fuel to simulate the effect of direct

injection (high compression ratio)

+ +

Rotax 654cc Aerocharger High Octane Gasoline

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How a Turbocharger WorksA turbocharger uses energy from exhaust waste heat to force more air into the combustion chamber.

http://www.aa1car.com/library/turbo_schematic.gif

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Power System Solution

Control System

The stock BMW engine control module (ECM) lacks important features required to run with a turbocharger.

• No cam position sensor• No mass air flow sensor

http://image.hondatuningmagazine.com/f/9329434/0704_ht_01_z+how_to_degree_a_camshaft+diagram.jpghttp://www.aa1car.com/library/ford_maf_sensor.jpg 19

Control System

Crank Position Sensor

O2 Sensor

Exhaust Temp Sensor

Throttle, TPS & Fuel

Injector

Spark Plugs

Engine Temp Sensor

Mass Air Flow Sensor

Engine Control Module (ECM)

Manifold Pressure Sensor

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The Experiment

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Fuel Economy Testing

EPA HighwayFuel Economy Cycle

(HWFET)

EPA City Fuel Economy Cycle

(FTP 72)

http://www.dieselnet.com/standards/cycles/ 22

Test SystemDrive cycle tests are performed on sophisticated motoring chassis dynamometers using complete vehicles.

• No test system available at BYU• No vehicle

http://www.autoequipexpo.com.au/xerxes/UserFiles/AutoEquipExpoandConvention/sydney08/dynamometer.jpg 23

Test System Solution

Steady-State Approximation of EPA Highway Fuel Economy Test Driving

Schedule

EPA Highway

Fuel Economy Schedule

Steady-state

Approximation

Length (s) 765 765Distance

(miles) 10.26 10.26Average

Speed (mph) 48.3 48.92

http://fueleconomy.gov/feg/images/hwfetdds.gif25

Fuel Consumption Data

Spec. Published Measured % Difference

Max. Torque

42 ft-lb @ 5250 rpm

46.5 ft-lb @ 5660 rpm

10.7% higher

Max. Power

53 hp @ 7000 rpm

53.5 hp @ 6346 rpm

0.9% higher

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Transmission Approximation

Model Assumptions:• Transmission is 85% efficient• Engine always at 3200 rpm• Vehicle + Driver weight = 2000 lbs.• Rolling Resistance coefficient = 0.025• Frontal Area * Drag coefficient = 7 ft2

Estimated HighwayFuel Economy

(no turbocharger):

54 mpg

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Moving Forward…

By tuning the turbocharger and control system:

• We expect more torque at every RPM.

• We expect to maintain fuel economy.

Next year, when we add direct injection, we expect to increase fuel economy to 60 mpg.

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Conclusion

With continued testing and tuning, we look forward to demonstrating the feasibility of the EME concept power system.

Eventually, the engine design will be incorporated into the PACE Emerging Market Vehicle.

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Questions/Comments

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