Proposal
< Shell Eco Fuel Efficient Vehicle >
by Saluki Engineering Company (SEC)
Reference number: F12-30-SECO
Team members:
Jia Huey Kong (JH)
Weishen Yee (WY)
Daniel Shawgo (DS)
Shi Wai Goh (SW)
Alex Eugene Lim (AL)
Date: 6th December 2012
i
Transmittal letter
November 6, 2012
Saluki Engineering Company
Southern Illinois University
Mail code 6603
Carbondale, IL 62901
iankong@siu.edu
SEIEC, Inc.
Mrs. Kay Purcell
Southern Illinois University
Mail code 6603
Carbondale, IL 62901
Mrs. Purcell,
This letter conveys the proposal project by SEC team 30 to design a fuel efficient vehicle for the
Shell-Eco marathon. On behalf of team 30, I would like to thank you for letting our team submit this
design proposal. The proposal is attached to this letter.
The proposal is based on using lightweight materials for the chassis with an aerodynamic frame in
conjunction with a fairly light gasoline engine not dissimilar to that of a go-kart. All of the
specifications that the vehicle must conform to will be met. The vehicle will be able to sit one driver.
Because this competition is based on fuel efficiency and that has influenced all of the design choices.
We are confident the proposal conforms to the Shell-Eco rules as well as the SEC’s requirements and
will place well in the competition. We look forward to the opportunity to work with your company. If
any more information is needed please contact me at the e-mail address above.
Thank you for taking the time to look at this project.
Sincerely,
Jia Huey Kong
Project Manager
ii
Executive Summary
The goal of the project is to create a vehicle with optimum efficiency regardless of
maximum speed or power. The specifications of the project are a 4 wheel vehicle with a
dimension of 150cm by 70cm by 65cm, the weight of the vehicle without the driver be of
approximately 120kg, the engine will be a gasoline single cylinder engine with 6.5hp output,
the expected maximum fuel consumption will be more than 500mpg. These specifications
were chosen in accordance to the rules of the Shell-Eco marathon competition for the year
2013.
The literature review included in this project consists of research done on engine
types, materials for the chassis, transmission types, aerodynamics, and types of ignitions. The
engine research was done to decide on what type of internal combustion engine would be
suitable for the project. The material research was done to find the most suitable material to
make the frame and shell of the vehicle, the material criteria were to be light and strong
enough to withstand the weight of the vehicle. Aerodynamics of the vehicle is important to
obtain the least amount of drag force thus increasing its fuel efficiency. The spark ignition
system was researched to find an ignition system for the engine and how the fuel efficiency
could be improved by controlling spark timing. The existing models from past year
competitors were researched to find potential problems and how their designs could be
improved.
The technical section shows how subsystems will interact with each other and how
the objective of the project can be achieved. The subsystems involved were the ignition
system, engine system, transmission system, chassis system, and brake system.
The budget shown in the commercial section is to ensure that the vehicle is
constructed with the lowest cost possible while still maintaining a high fuel efficiency vehicle.
iii
Constructing of the prototype will commence next semester while parts will be ordered at the
end of this semester. The estimated cost of building the prototype is approximately $1400.
iv
RESTRICTION ON DISCLOSURE OF INFORMATION
The information provided in or for this proposal is the confidential, proprietary property of
the Saluki Engineering Company of Carbondale, Illinois, USA. Such information may be
used solely by the party to whom this proposal has been submitted by Saluki Engineering
company and solely for the purpose of evaluating this proposal. The submittal of this
proposal confers no right in, or such information for sale. All drawing, specifications, and
other writings supplied with this proposal are returned to Saluki Engineering Company
promptly upon request. The use of this information, other than for the purpose of evaluating
this proposal, is subject to the terms of an agreement under which services are to performed
pursuant to this proposal.
v
Table of content
Number Content
1
Introduction
2
Literature review
 Clutch and transmission
 Aerodynamics
 Engine
 Existing systems
 Ignition sysrem
3
Technical section
 Overall block diagram
 Transmission subsystem block diagram
 Hydraulic system block diagram
 Chassis block diagram
 Ignition system block diagram
 Engine block diagram
4
Team organization
 Team chart
5
Commercial section
 Project cost estimate
6
Management section
 Spring 2013 tentative timeline
 Spring 2013 AIL
7
List of experiments
8
List of deliverables
9
Appendix
 Lower and higher heating values chart for liquid and solid fuels
 Team resumes
 Reference
Page
1
2
3
6
9
10
12
13
15
17
18
19
20
21
22
23
24
25
26
27
33
vi
List of tables
Table Number
Title
Page
Table 1
Examples of the drag coefficient of different vehicles are shown
4
in the table
Table 2
Material strength to weight ratio comparison
5
Table 3
Comparison of the advantages and disadvantages of the four
6
different fuels
Table 4
Comparison of fuel types 7
7
Table 5
Otto cycle and diesel cycle engine comparison
8
Table 6
Cost estimate of project
21
Table 7
Spring 2013 tentative timeline
22
Table 8
Spring 2013 AIL
23
vii
List of figures
Figure Number
Title
Page
Figure 1
Pressure- Volume diagram of an Otto cycle
9
Figure 2
Overall block diagram 12
12
Figure 3
Transmission block diagram
13
Figure 4
Brake system block diagram
15
Figure 5
Chassis block diagram
17
Figure 6
Ignition system block diagram
18
Figure 7
Engine block diagram
19
Figure 8
Team chart
20
viii
Introduction
The objective of this proposed project is to build a fuel efficient internal combustion
engine vehicle system.
The motivation behind this project is that our world is dependent on fossil fuel to
drive the economy and technological growth. A fuel efficient internal combustion system will
definitely be more cost efficient and environmental friendly, especially due to the increasing
fuel price that the world is currently experiencing. This allows the invention and innovation
of more economical family vehicles, delivery vehicles, and public transports. Consuming less
fuel is also relatively more environmental friendly as less fuel burnt meaning less greenhouse
gasses are released into the atmosphere. Thus this helps to keep the air clean and diminishes
the existence of global warming.
1
Literature review
Clutch and transmission
The purpose of the transmission system is to supply the amount of torque as needed
when switching from high to low gear; it also avoids potentially damaging the engine due to
sudden increase in speed [1].
The 5 speed manual transmission system uses multiple gears of different size to get
the appropriate gear ratio to produce the required torque. The manual transmission allows the
user to switch between gear ratios using a shift stick connected to the gear box [2].
CVT is a transmission system which instead of using gears uses pulleys with variable
diameter to change the torque output of the engine. The variable diameter of the pulleys is
controlled by flywheels and torque load applied on the drive shaft; this allows the CVT
system to deliver the optimum horsepower power needed to the vehicle, hence fuel efficiency
is at its maximum [4].
The CVT system is more suitable for the purpose of this project because, it is more
fuel efficient; because the CVT system is continuously variable it avoids gear jumping as
seen in manual system which causes loss in efficiency. A CVT system is also calibrated to
choose the best pulley ratio to get the optimum performance base on the load torque on the
vehicle instead of relying on the driver’s skill causing inefficiency.
The CVT system itself is also lighter as it only comprises of a torque sensor, flywheel,
two pulleys and a belt while the manual system consist of multiple gears each made of cast
iron resulting in a heavier system; the decrease in load on the vehicle allows for reduced fuel
consumption.
In addition to that CVT transmissions also allow for easier maintenance due to the
smaller number of parts and its simpler build mechanism. [3]
2
Aerodynamic of shell eco car
Aerodynamic is the study of moving gases over a body. At highway speeds, the
estimated resistance of a rolling tire is approximately 25%, air drag is 60% [7]. In order to
improve fuel efficiency of a car, the shape of the car plays an important role on it. Air
resistance can be reduced by incorporating a good aerodynamic design to the shell of the
vehicle; this in turn would increase the fuel efficiency of the vehicle. According to the article
“passenger car aerodynamic” by Warren Beauchamp[5]. "an average 3000 pound car driving
at a speed below 90MPH, the down force of the vehicle could be neglected." Since the
objective is to achieve maximum fuel efficiency, parts such as spoiler wings and others parts
which create a downward pressure in order to keep the car low are neglected in the design
processes. An oval tubing shape allows air flow to stay smoothly attached. Therefore, an
ideal body for a car would be like a teardrop shape.
Firstly, drag coefficient (Cd) is responsible for drag acting on the vehicle. The more
aerodynamic the shape of the shell the smaller the drag coefficient. The best coefficient drag
for a car is 0.28 [5]. The formula for the drag coefficient of a car is
Cd= 2Fd/ A(ρV2) , where
Fd= drag force
A=reference area
ρ= density of the fluid
V=free stream velocity measured relative to body.
3
By inserting the data into the formula above, the drag coefficient of the car could be
calculated.
Table 1, Some examples of the drag coefficient of different vehicles are shown in the table.
Type of Object
Drag Coefficient, cd Frontal Area, A
Old Car like Model T-Ford
0.7 - 0.9
frontal area
Modern Car like Toyota Prius
0.26
frontal area
Sports Car, sloping rear
0.2 - 0.3
frontal area
Streamline body
0.04
π/4d2
[6] From the table above, undoubtedly streamline body has the lowest drag coefficient,
therefore the design chosen was as close to a stream line body as possible. However, in
reality it is impossible to have an ideal shape for the car. Reducing the size of grill can help to
minimize frontal pressure and with a minimal ground clearance below the grill, this
minimizes air flow under the car [6].
Material selection for body of car
In order to increase the fuel efficiency of the shell eco-marathon vehicle, the weight of the
body must be minimum but at the same time strong enough to support the weight of the
engine and the driver. A few materials were looked into for its high strength to weight ratio
are aluminum, carbon fiber, magnesium alloy and wood.
Nowadays, aluminum is one of the popular materials chosen in automobile industries.
For a modern car, aluminum body design can reduce the weight by 24% compared to steel.
Fuel consumption was reduced by 2 liters per 100 kilometer due to the reduction in weight.[8]
Steel can now be completely replaced by advanced high tensile alloys to build the vehicle
body. According to Audi engineers [8], the model A8 Audi is made of high tensile aluminum,
which reduces the weight by approximately 239 kg. Besides Audi, others manufacturers like
Mazda, Jaguar, BMW, used aluminum to build their car bodies.
4
Carbon fiber has a very high modulus of elasticity compared to steel. Among the
advantages carbon fiber have are high tensile strength reach of approximately 7GPa, a low
density of (1800kg/m3) and high chemical inertness [9]. However, carbon fiber is brittle and
tends to fail suddenly.
From the table shown, Spectra fiber has the highest strength to weight. However, the prices
for carbon fiber is much higher compared to steel. Its price is 20 times much higher compared
to steel [10].
Magnesium alloy is another material that being used in automobile industries. The
advantage of magnesium alloy is its light weight [15]. According to the research been done in
Germany, the magnesium door weighs about 10 lbs., where a standard steel door would
weigh approximately 23.5 lbs. which 13.5 pounds lighter than the steel [15].
Table 2,Material strength to weight ratio comparison
Materials
Strength to weight ratio
Spectra fiber
3619
Carbon Fiber
2457
Aluminum alloy
222
Magnesium alloy
158
Steel alloy
254
5
Engine subsystem
The Shell Eco- Marathon (US) competition consisted of four categories of fuel;
regular 87 (US), diesel, biodiesel (fatty acid methylester), and ethanol 100 (100% ethanol).
Table 3, The advantages and disadvantages of the four different fuels.
Gasoline
Regular 87
(US)
Diesel Fuel
Ethanol
(E100)
Advantage
 Average energy per liter of
fuel.
 Energy per liter of fuel is
higher than E100 and
Biodiesel.
 Does not need spark to ignite
fuel.
 Have highest content of
energy per liter of fuel.



Biodiesel


Disadvantage
 Need a electrical spark plug to
ignite fuel.

Low cost fuel
Reduce foreign oil coming in
the country.
Burns cleaner air than
gasoline.

Reduce greenhouse
emission; better than diesel
and gasoline.
Biodegradable



In cold climate, diesel fuel
turns cold and thus the
viscosity of increases
resulting a slow flow rate in
fuel which is difficult to inject
into the cylinder
Cold climate, enthalpy of
vaporization increases, cause
problem starting the engine.
Lowest energy content
compared to gasoline, diesel
and biodiesel.
Low fuel economy and power.
Lower than diesel and
approximately the same as
gasoline.
Cold climate, viscosity
increases.
Table 1 shows the comparison of gasoline, diesel, ethanol and biodiesel.
The goal of this project is to achieve the most fuel efficient prototype vehicle. The
fuel is a fixed variable and the responding variable is the mileage run by the vehicle.
Generally, the higher the content of energy of fuel per gallon provides us a greater mileage.
Table 2 shows the energy content per (US) Gallon of each fuel.
6
Table 4, Comparison of fuel types
Octane number
Energy per gallon
(Btu/gal.)
Gasoline
86 to 94
116, 090 -124, 340
Diesel
8 to 15
128, 450 – 137, 380
Ethanol (E100)
129
76, 330 – 84, 530
Biodiesel
~25
119, 550 – 127, 960
Table 2 shows the energy content per US gal extracted from Appendix A [12].
Internal combustion engine (ICE) fuel is ignited in a combustion chamber and highpressure gas expansion causes the cylinder in the engine to move in linear motion. There are
two types of cycle to model the internal combustion engines; the Otto cycle is used to model
gasoline engine and the diesel cycle is used to model diesel engine.
Table 5, Otto cycle and diesel cycle engine comparison
Otto Engine
Homogenous fuel and air is mixed together
in the carburetor is pumped into the cylinder.
Spark plug ignites the fuel.
Diesel Engine
No carburetor is used. First, Air is
compressed by the cylinder. Fuel is injected
into the cylinder at the end of compression.
Fuel is ignited.
Electric spark plug needed ignite the fuel.
No electrical spark plug. High temperature of
air and fuel mixture ignites the fuel.
The throttle valve in the carburetor mix fuel
No throttle value is used. The mass of fuel
and air varies with power output.
injected into the cylinder varies with power
output.
Table 3 shows comparison between Otto engine and diesel engine [13].
Otto cycle is modeled as an ideal cycle. It consists of four processes that are used in
the field of engineering to analyze the efficiency of the engine, energy into the system and
out of the system, and heat energy into the system and out of the system. There are four
7
processes in this cycle; air and fuel intake, compression, power stoke and exhaust. Figure 1
shows Pressure- Volume diagram of an Otto cycle.
Figure 1 shows Pressure- Volume diagram of an Otto cycle [14].
The general expression for efficiency of the Otto cycle is
1. η =
work
heat input
, where
η is the thermal efficiency
8
Compare and Contrast with existing models
A custom designed single cylinder, four-stroke internal combustion engine running on
gasoline is usually used to power prototype vehicles in the past Shell Eco competition. There
were teams operating their engines at wide open throttle for a short burst then switched off to
let the vehicle coast to conserve fuel. This cycle is repeated in what's called a "burn and
coast" method. Teams usually improve the ignition performance by adjust the spark timing,
ensure a high compression ratio without engine knock, the use of a low fuel to air ratio
without misfire, and minimization of mechanical friction. Engines are usually insulated in
order to keep the engine warm to increase fuel vaporization and decrease heat loss.[15]
9
Ignition system and spark timing
The basic premise of an ignition system is to ignite the fuel in the engine to drive the
pistons. With a well-timed, if not perfectly timed, spark one can get more efficiency out of
the engine. However if the spark is not timed well then the engine can cost power and fuel.
Crank triggers are a newer way of ignition, due to its precision in timing [16]. These triggers
have been used in racing where fuel efficiency can be a key factor in winning and the
company (Clements Racing Engines) has been using them whenever allowed as of 2004 [17].
In something like a lawn mower a rip cord can be pulled to rotate a flywheel, this flywheel in
conjunction with a crankshaft causes a current due to inductance. This current then triggers
the spark plug to start the engine [17]. Normal car engines can take up to ten elements in
conjunction with each other to start up the spark plug at the correct time [18].
Ignition systems can get extremely complex, with things like fuel injection and
perfectly timed sparks as well as the constant innovation that compounds the complexity.
Spark plugs can either run hot or cold depending on the engine type and if the spark plug runs
too hot it can ignite the fuel before a spark [18]. Other factors to consider is if the engine has
multiple pistons to run and therefore multiple sparkplugs then a distributor (a device that
distributes voltage) must be used and must distribute the voltage at the correct time to
maximize efficiency [18].
In closing the ignition system is complex but can contain few parts (such as in the
case of a rip cord ignition system) which lessens the complexity. At the other end of the
spectrum there are very technical books to help design ignition systems. Such books go over
all aspects of engines as well as things like pictures of fuel injection spray compared with
perfect models of the aforementioned.
10
Technical section
The objective of the system is to achieve optimum fuel efficacy, the sub systems
involved are the chassis, the engine, the transmission, the spark and ignition, and the brake
system. These system interact together to allow the vehicle to function properly. The
transmission, the spark and ignition, engine and chassis subsystem have a large effect on the
vehicle mileage. To optimized the fuel consumption of the vehicle the chassis sub system
must be light and aerodynamic, the spark timing must be optimize, the air fuel ratio needs to
be optimized, and the transmission needs to be calibrated to the engines output.
11
Over all block diagram
Figure 2, Overall block diagram
12
Transmission sub-system (JH)
Figure 3, Transmission block diagram
The CVT transmission sub system functions to optimize the power use of the engine
output. It changes the pulley size ratio according the torque load and speed acting on the
transmission. By switching pulley ratios to supply the right amount of power for acceleration
the transmission subsystem can increase fuel efficiency. Test and calibrations on the flywheel
and torque controller will be performed to optimize the output of the engine in the vehicle.
The transmission sub-system is a variable diameter pulley system. The system
consists of two variable diameter pulleys, a fly wheel and a torque controller. The driver
pulley is called the primary pulley and is connected to the crankshaft of the engine; it consists
of two parts the stationary sheave and the movable sheave. The fly wheel is a mechanism that
consists of clutch weights and a pressure spring which controls the diameter of the driver
pulley. The belt connecting the two pulleys is a v-belt which allows for better friction
between the belt and pulleys as the diameter changes. The driven pulley is called the
secondary pulley and consists of two sheaves stationary and movable. The secondary pulley
13
movable sheave is connected to the torque controller which controls the diameter depending
on the torque output of the transmission.
The movable sheave, stationary sheave, and fly wheel are connected to the crank shaft.
The fly wheel is also connected to the movable sheave through pressure spring, roller and
clutch weight. As the fly wheel rotates the centrifugal force on the clutch weight allows it to
overcome the tension of the spring and push the movable sheave towards the stationary
sheave effectively increasing the radius of the pulley; as the angular velocity decreases the
clutch weight retracts and spring pulls the movable sheave away from the stationary sheave
decreasing the radius.
The secondary pulley’s movable and stationary sheaves are connected to the output
shaft. The movable sheave is also connected to the torque controller. The torque controller
pushes the movable sheave closet to the stationary sheave causes the pulley to squeeze the v
belt increasing the radius when the engine is under a high rpm which increases the power
output.
The one problem that might occur when using such a system is finding the proper
calibration for the engine output to ensure maximum efficiency. Proper spring constants,
clutch weight, and torque controllers are required to get maximum efficiency.
14
Figure 4, brake system block diagram
Hydraulic brake system
Brake pedal is the first component that starts the hydraulic system. By applying certain
amount of forces to the brake pedal, the brake pedal will pushed the piston in the master
cylinder, and create pressure on the hydraulic fluid and allow it to flow through the brake
15
lines. The break lines are connecting to the front and rear brakes. Therefore, once the force is
applied on brake pedal the hydraulic fluid will flow through the whole brake system.
Front brakes, is made up of few components which are, brake calipers, brake pads, brake disk
and a small piston cylinder. When the pressure of hydraulic fluid applied on the piston, the
piston will push the brake calipers, and the brake calipers will push the brake pad and create
amount of forces to clamp on the brake disk. This is basically how the hydraulic brake stops
the wheels from moving.
For the rear wheel, the components are slightly different from the front wheels such as
primary shoes lining, break lever and wheel cylinder. Break drum are made of iron and have
a machined surface on the inside where the shoes make contact. Wheel cylinder in drum
brake consists of two pistons. When the hydraulic liquid applied pressure on the piston, it will
force the rubber seal on the piston pushing the shoes into contact with the drum and causing
the wheel from moving.
Emergency brake
Emergency brake is a backup braking system designed to function even when there is total
brake failure. Applying the emergency brake will immediately cause the steel cables to pull
the lever in the rear brake and swivels the primary and secondary brake shoe. The secondary
brake shoe will fall in to the brake drum and cause the rear tires form stop moving.
16
Figure 5, Chassis block diagram
A chassis consists of an internal framework that supports an entire vehicle. The
chassis on the prototype will consist of the frame, engine, transmission, driveshaft, throttle
and brake pedals. An engine mount connects the engine to the chassis. The crankshaft is then
connected at the output of the engine to the CVT transmission and the prototype is designed
with a back wheel drive the transmission is connected to the back wheels via a live axel. The
seat is placed at a certain angle and is connected to the chassis through regular brackets. The
front wheels are connected to a spindle and following with tie rods to the steering wheel. The
steering system is connected to the chassis through a steering column that is mounted on the
chassis. The brake pedal is connected to the chassis through regular nut and bolts while a
string is also attached to it to ensure the pedal returns to its original position after pressing on
it. Two sets of brake calipers are connected to the pedal via wires and a hydraulic system is
used to force the brake pads on to the front wheels. A similar system is used for the throttle
17
pedal where it is connected to the chassis by bolts and attached to a spring for the same
reasons as the brake pedal. As the throttle pedal is pushed, wires connected from the pedal to
the throttle lever in the engine will be affected by the tension of the wires.
Spark and ignition
Figure 6, ignition system block diagram
High voltage is fired off through the primary winding by the ignition coil after the
ignition has been activated. The secondary winding acts as a step up transformer and a
voltages of up to 5000V was created to jump the gap and make your spark plug fire. This
ignites the gas/air mixture in the engine to start the pistons. The spark plugs will continue to
spark in order to keep the pistons turning, the frequency of the sparks depends on the type of
spark plug and engine.
Engine subsystem
The gasoline engine that is used in this project consist of one cylinder, thus there is
only one working spark- plug in the system to ignite the fuel. Figure 1 shows a more specific
block diagram of an engine subsystem. First, air and gasoline fuel is mixed in the carburetor
18
with the amount of air/ fuel ratio. The right amount of air/ fuel ratio is determined using
stoichiometric ratio. Air and fuel from the carburetor is then injected in to the cylinder block
through fuel injection valve. Air and fuel is compressed by the cylinder under high pressure.
Gasoline fuel requires a spark plug to ignite the fuel, thus each cylinder block have a spark
plug to ignite the fuel. A sudden explosion occurred in the cylinder causing both pistons to
push backwards; expansion process occurred. The piston is connected to a crankshaft. The
explosion in the cylinder caused the both piston to move in linear motion. The function of a
crankshaft converted linear motion from the piston to a rotational motion. Crankshaft is
connected to the flying wheel. Flying wheel is a rotating mechanism store rotational energy,
provide continues energy, deliver energy and control the orientation of the mechanical system.
The flywheel is connected to transmission sub- system that controls the gear ratios.
Figure 7, engine block diagram
19
Team chart
Figure 8, Team chart
20
Commercial section
The estimated budget for all the materials and equipment is approximately $1,200.
Table shown below is the breakdown of the budget.
SE-Project budget
Item list
Estimate Cost
Quantity
Store
Go-Kart
$600
1
Fiber Glass Materials
Transmission cost
Carbon fiber frame
Safety Devices
$120
$150
$120
$80
Acrylic plastic sheet
Wind tunnel
ANSYS Program
Dynamometer
Ceramic coating
Total
$100
on hand
on hand
on hand
$50
(produce 33m² area)
1
$12.3 per tube (2m long)
Rear mirrors (2), seat belt, fire
extinguisher
24" X 48"
1
1
2
$1,220
eBay or online
supplier
cstsales.com
eBay
cstsales.com
amazon
online supplier
Table 6, Project cost estimate
21
Management section
Parts will be ordered during the 20th of November 2012 and prototype building will start on
the 9th January 2013. The schedule for next semester is;
Table 7, Spring 2013 tentative timeline
22
AIL for spring 2013
Table 8, Spring 2013 tentative timeline
23
List of Experiments
Power is a product of force and linear velocity and in rotational, it is a product of torque
and angular velocity. In order to measure the power of the engine, force, torque, linear and
angular velocity must be determine. A dynamometer can measure the force and torque
whereas; a tachometer can measure the linear and angular velocity. Once the torque and
angular speed is found, the break power (bp) can be determine using equation 1.
1. break power, bp =
2πRτ
60
Where, τ is the torque and r is the rotational speed.
To calculate the mechanical efficiency of the engine, the indicated power (ip) is needed.
Equation 2 shows how to calculate value of ip.
2. indicated power, ip =
pARk
60
Where, p is a mean pressure, A is the area of the piston and k is the number of cylinders.
Thus, the mechanical efficiency is defined as the ratio of break power to indicated power.
Equation 3 can determine the mechanical efficiency.
3. Efficiency, E =
bp
ip
bp
= bp+fp
There are some friction lost in the cylinder wall, pistons and viscosity of engine oil. The
difference between indicated power and break power is the friction power shown in equation
4.
4. Friction power, fp = ip − bp
24
To calculate the fuel consumption of the prototype an external gas tank will be built onto the
vehicle and the mass of fuel before and after the test will be taken to determine the fuel
consumption
Description of project
The vehicle built will meet the following specifications and be in accordance with the
shell eco 2013 rule and regulations. Our design consists of a chassis together with a single
cylinder 6.5hp gasoline spark ignition engine. By adjusting the spark timing, we will be able
to ensure that the combustion process in the pistons will take place at the right timing and
thus increase the average miles per gallon travelled. Engine knocking will also be prevented
to ensure that unburned fuel will not go to waste. We will also be insulating the engine to
decrease heat loss and increase fuel vaporization.
The best combination for the project vehicle is a teardrop stream line shaped carbon
fiber chassis, gasoline engine, and manual or CVT system. Funding and budget may be a
limiting factor on materials, so further research to find cheaper and more effective methods of
increasing fuel efficiency is required to continue the design the vehicle.
25
Deliverables of project
Design consists of 4 wheels ( 2 front and 2 rear )
Length = 150cm
Width = 60.96cm
Weight without driver = 120kg
Engine type = single cylinder 6.5hp engine
Fuel type = Gasoline
Ignition = Spark ignition
bore/stroke = 73mm*58mm
Compression ratio = 8.2 : 1
Max Power Output = 3600rpm
Max Torque = 17N.m / 2500rpm
Average Miles per gallon = 400mpg
Brake type = Hydraulics
Safety features

Fire extinguisher

Emergency shutdown (internal and external)

2 rear view mirrors

Shatter proof windscreen

Emergency brakes
26
Appendix
Appendix A: Charts
27
Appendix B: Team member resumes
SHI WAI GOH
Carbondale, Illinois 62901 ● andygsw@siu.edu ● (618)434 0790
EDUCATION
Southern Illinois University
Bachelor of Science Degree in Mechanical Engineering
Overall GPA: 3.0
Major GPA: 3.4
SKILLS
Microsoft Words
MATLAB
Microsoft Excel
AutoCAD
Carbondale
June 2013
Class level: Senior
Microsoft PowerPoint
Microsoft Visual Studio C++
MECHANICAL ENGINEERING PROJECTS
 Trebuchet: Together with three other mechanical engineering undergraduates design,
assemble, and test a trebuchet.
 Bottle Rocket launcher: Volunteered to lead several groups of high school students to design,
assemble and successfully launch a pressurized bottle rocket during engineering day.
 West Point Bridge Designer: Designed a virtual bridge on the West Point Bridge Designer
Software and provide the most cost effective method and material to construct the bridge.
 Shell Eco-Marathon: Designing and building a medium scale prototype of a diesel engine
vehicle with a goal of maximizing its overall efficiency by using methods such as spark
advancing, tweaking the air fuel ratio of the engine, determining the best shape and material to
obtain the best miles per gallon of fuel.
RELAVENT COURSEWORK
Thermodynamics
Materials Selection
C++ Programing
Mechanics of Materials
LANGUAGE
English
Heat Transfer
Engineering Economics
Mechanical Analysis in Design
Air Pollution Controls
Chinese Mandarin
Chinese Cantonese
Fluid Mechanics
Machine Design
Manufacturing Processes
Malay
AWARDS and MEMBERSHIP
Awards
 Dean’s List (2011 – Present)
Membership
 Tau Beta Pi, National Engineering Honor Society (2011 – Present)
28
Carbondale, IL 62901
Jia Huey Kong
iankong@siu.edu 618-305-4687
EDUCATION
SOUTHERN ILLINOIS UNIVERSITY
Bachelor of Science Degree in Mechanical Engineering
Overall GPA: 3.780
Major GPA: 3.883
Carbondale
May2013
SKILLS
AutoCad
Microsoft Word
C++ programming
Microsoft Excel
AutoDesk Inventor
Microsoft PowerPoint
SolidWorks
Matlab
MECHANICAL ENIGINEERING PROJECTS
 Shell-eco marathon: Worked on creating a fuel efficient vehicle to participate in the shell eco
competition in Houston, Texas, April 2013
 Break pad design: Worked on parametric modeling of a break pad using Autodesk inventor and FEA
 Internal combustion engine- Researched on the effects of spark retardation and crank shaft speed on the
engines power
 Six Sigma- Used six sigma to reduce the error in an experiment using a “target game”
 Bottle rocket- Lead high school students through the design, and creation of a fully functional bottle
rocket powered by air pressure
 Trebuchet project: Directed a team of four in the conception, design, construction, and presentation of a
fully functional Trebuchet and entered in a completion.
 West point bridge program- Created a bridge using the program that can withstand its own weight and
the weight of a truck
RELEVANT COURSEWORK
HVAC Systems Design
Heat Transfer
2012
AREA OF SPECILIZATION
Fall 2012
Summer
Mechanical systems
VOLUNTEER EXPERIENC
 Volunteer in Student RSO fair- SIU, IL
August 2012
Assisted in promotion of student club and associations, and worked with different people
 Vice president of SIU Aikido club, SIU-IL
August 2011
Assisted in drafting club proposals for budgets, funding requests, and helped organized trips
 Attended student leadership program, SIU-IL
August 2011
Learnt how to run student organizations, procedures, and developed leader ship skills
LANGUAGE
Chinese, Cantonese (Basic)
Japanese (Basic)
Malay
English
AFFILIATIONS
 Dean’s list (spring 2011, summer 2011, fall2011, spring 2012, summer 2012)
 Tau Beta Pi (fall 2011)
29
Weishen Yee
Carbondale, Illinois 62901 ● yeeweishen@siu.edu ● (347)433 3215
EDUCATION
Southern Illinois University
Bachelor of Science Degree in Mechanical Engineering
Overall GPA: 3.430
Major GPA: 3.609
SKILLS
Microsoft Words
MATLAB
Microsoft Excel
AutoCAD
Carbondale
May 2013
Microsoft PowerPoint
Microsoft Visual Studio C++
MECHANICAL ENGINEERING PROJECTS
 Trebuchet: Together with three other mechanical engineering undergraduates design,
assemble, and test a trebuchet.
 Bottle Rocket launcher: Volunteered to lead several groups of high school students to design,
assemble and successfully launch a pressurized bottle rocket during engineering day.
 West Point Bridge Designer: Designed a virtual bridge on the West Point Bridge Designer
Software and provide the most cost effective method and material to construct the bridge.
 Piston and Rotary Engine Internal Combustion: Studied the effects of crank angle and richness
of fuel mixtures against engine power.
 Target Game: In a group of 7, we used six-sigma structure to improve the quality of a product
by identifying the Critical to Quality characteristics of the product and narrowing down to the
three most influential causes.
 Shell Eco-Marathon: Designing and building a medium scale prototype of a diesel engine
vehicle with a goal of maximizing its overall efficiency by using methods such as spark
advancing, tweaking the air fuel ratio of the engine, determining the best shape and material to
obtain the best miles per gallon of fuel.
RELAVENT COURSEWORK
Thermodynamics
Engineering Economics
Engine Combustions
Mechanics of Materials
Heat Transfer
Machine Design
Mechanical Analysis in Design
Air Pollution Controls
Materials Selection
C++ Programing
Manufacturing Processes
Fluid Mechanics
EXPERIENCE
Southern Illinois University, College of Engineering Dean’s Office . 1230 Lincoln Dr., Carbondale, IL
Clerical Position
(June - August 2012)
Assisted in managing the associate dean’s daily schedule through Google calendar.
Provided assistance to the dean’s secretary in photocopying confidential office documents.
Answered telephone calls that were directed to the dean’s office and assists in answering questions.
LANGUAGE
English
Chinese Mandarin
Chinese Cantonese
Malay
INVOLVEMENT, AWARDS and VOLUNTEERING SERVICE
Awards
 Dean’s List (2011 – Present)
 King’s Scout award, highest honor award for global scouting movement (2009)
Involvements
 Tau Beta Pi, National Engineering Honor Society (2011 – Present)
 International Student Orientation (August 2011)
30
Alex Eugene Lim
900 E. Grand Ave. 117
Carbondale, IL 62901
(618) 319 5089
limeugen3@gmail.com
EDUCATION
Southern Illinois University at Carbondale, IL.
Bachelor of Science in Mechanical Engineering (Expected Graduation: May 2013)
WORKING EXPERIENCE
Sea Automation Std. Bhd., Kuala Lumpur, Malaysia.
Computer Technician (September 2010 – December 2010)
 Provided customer services regarding various computer hardware, software and accessories
problem.
 Engaged with company’s suppliers and checked stock.
 Helped assemble a computer laboratory for orphanage home.
VOLUNTEER WORK
International Orientation Week
 Helped new students to organize their VISA and international documents before meeting
officers.
Midwest Games International 2012 at University of Illinois at Urbana- Champaign
 Became a referee for sport games.
 Made clear explanation regarding the rules of sports and fair play.
SKILLS
 Computer: Autodesk Inventor PRO 2012, AutoCAD 2011, Microsoft Word, Excel, PowerPoint
and Visual Studio (C++ programming).
 Languages: Conversational Mandarin and Malay.
ACTIVITIES
Malaysian Student Association at Southern Illinois University
Vice President (August 2012 – Current)
 Conduct monthly meetings and agendas.
 Encourage member’s involvement within the association and boost up productivity.
 Create and coordinate event with other associations in Carbondale and Midwest Region.
Shell Eco-Marathon Americas
 Senior design project.
 Modeling and designing a prototype car that have the best fuel efficient.
RELEVENT COURSE WORK
 Materials Selection
 Numerical Methods
 Differential Equation
 Computer-Aided Engineering Design




HVAC Design
Heat Transfer
Statics and Dynamics
Fluid Mechanics
ACHIEVEMENTS
Dean’s List (Spring 2011, Summer 2012) College of Engineering at Southern Illinois University
Carbondale
31
900 S Elizabeth St Apt 5,
Carbondale, IL, 62901
Phone (618)-203-0146
E-mail
WordlessOnijak@yahoo.com
Daniel Shawgo
Objective
Education
To gain work experience that will allow the application of skills and
knowledge acquired at SIU.
2010-2012
Southern Illinois University
Carbondale, IL
College education
Southern Illinois University at Carbondale, IL.
Bachelor of Science in Electrical and Electronics Engineering
Skills

Type 70+ words a minute.

Ability to use AutoCAD, Solidworks, and various Microsoft Office
programs.

Experience with cadence.

Programming experience in C++ and VHDL/Verilog
32
Reference
[1] Eric Tallberg, "What is a Transmission?" [Online]. Available:
http://www.wisegeek.org/what-is-a-transmission.htm#
[2] Marshall Brain, "How Manual Transmission Work?" [Online]. Available:
http://auto.howstuffworks.com/transmission.htm
[3]"CVT vs 5-speed Comparison Chart?" [Online]. Available:
http://www.insightcentral.net/KB/faq-cvt.html
[4]Aron Gold " CVT - Continuously Variable Transmission" [Online]. Available:
http://cars.about.com/od/thingsyouneedtoknow/a/CVT.htm
[5] Warren Beauchamp, "Passenger Car Aerodynamics," May.2009. [Online]. Available:
http://http://www.recumbents.com/car_aerodynamics/.
[6] No Author, "The drag coefficient expresses the drag of an object in a moving fluid,"
[Online]. Available: http://www.engineeringtoolbox.com/drag-coefficient-d_627.html
[7] R. Kayne & L. S. Wynn, "What are Car Aerodynamics?" [Online]. Available:
http://www.wisegeek.com/what-are-car-aerodynamics.htm.
[8] R. Kayne &, "Aluminium in the automotive industry," [Online]. Available:
http://www.aluminiumleader.com/en/around/transport/cars.
[9] Dmitri Kopeliovich, "Carbon Fiber Reinforced Polymer Composites," [Online]. Available:
http://www.substech.com/dokuwiki/doku.php?id=carbon_fiber_reinforced_polymer_
composites
[10] Lee Riedinger, "Carbon-Fiber Composites for Cars," [Online]. Available:
http://www.ornl.gov/info/ornlreview/v33_3_00/carbon.htm
[11] P.L. Gan, "Wooden Electric Car Steals Limelight at Shell Eco-Marathon Asia," July.
2012. [Online]. Available: http://theenergycollective.com/node/91321
[12] Argonne National Laboratory. (2010, August). GRERT, The Greenhouse Gases,
Regulated Emissions and Energy Use in Transportation Model. GREET 1.8d.1.
Available: http://greet.es.anl.gov/
[13] Shet U.S.P., Sundararajan T. and Mallikarjuna J.M. Gas Power Cycle. Available:
https://docs.google.com/viewer?a=v&q=cache:CruuuUlN0yUJ:nptel.iitm.ac.in/course
s/IIT- MADRAS/Applied_Thermodynamics/Module_4/
[14] National Aeronautics and Space Administration, NASA. (2008, July). Ideal Otto Cycle
P- V Diagram. Editor: Benson, T., Available: http://www.grc.nasa.gov/WWW/k12/airplane/otto.html
[15] U Ottawa Supermileage, online, http://uosupermileage.ca/vehicle/engine
[16] J. Huneycutt, “Crank-Trigger Ignition – Double-Timed,” circletrack.com. [Online].
Available:http://www.circletrack.com/enginetech/ctrp_0412_crank_trigger_ignition/v
iewall.html. [Accessed: Oct. 02, 2012].
33
[17] E. Blankenburg, “How to Check Ignition Systems on Lawn Mowers,” ehow.com.
[Online]. Available: http://www.ehow.com/how_10028322_check-ignition-systemslawn-mowers.html. [Accessed: Oct. 02, 2012].
[18] K. Nice, “How Automobile Ignition Systems Work,” howstuffworks.com. [Online].
Available: http://auto.howstuffworks.com/ignition-system.htm. [Accessed: Oct. 02,
2012].
34