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Goals
Goals
- 2 Full Rotations Minimum
- Bare minimum to prove it worked
- 4 Cylinders
- Any less is boring
- 50 RPM
- After doing the math, this seemed like a fine number to achieve realistically
Engine Layout
Engine Layout
- Flat 6 purely because I like it
- Although it turns out to be an excellent choice for this application for many reasons
Flat 6 & Engine Configuration Design Impacts
Flat 6 & Engine Configuration Design Impacts
- Crankshaft Length
- Crankshaft Complexity
- Engine Balance
- Engine Size
- Powerstroke Overlap
- Pros
- No Counterweights needed
- Perfect Engine Balance
- Short Crankshaft
- Cons
- Assembly Complications
- Less iconic
- Not recognizable to most
- Wide
Onshape
Onshape
- Second Project in Onshape
- Evaluation
- Version History is amazing for documentation and prototyping
- Allowed me to feel safer taking bigger design risks at a time because everything was saved
- Multiple computers is always nice
- This project did not actually really take huge advantage of Onshape benefits
Prototype 1
Prototype 1
- Good
- SPINS!
- Held Air Pretty Ok
- Bad
- FRICTION
- Everywhere, all over, doing bad things
- Connecting Rods not secured well
- Almost 0 Thread engagement due to no material and impossible assembly
- Still have all the electronics to do
- Solenoids will be hard to wire because of the voltage and amps required
- Pretty Leaky
- Oh it also blew up
Copy of IMG_3394.mov
Iterate
Iterate
- Tolerance War
- Robust Parts
- Rebuild Engine
- Fine Tuning
Weighting Problems & Fine Tuning
Weighting Problems & Fine Tuning
- Layer Line/Layer Line Friction
- Wobble & Con Rod Confusion
- Crankshaft Strength vs Friction
- Holding Air
Electronics
Electronics
- Mobility was a must
- Understanding the relay
- Problems
- Faulty barrel connector
- Bizzare relay behaviour
- Pin 13???
- Did what it needed to
- Big point of growth for me
Programming (KISS)
Programming (KISS)
- Picked this project keeping in mind that I wanted the code to be simple
- Learned about Struct
- Sort of
- Modular code for easy test & tune
Copy of IMG_3920.movOverview
Overview
- 130cc
- 1.5in Bore / 0.75in Stroke
- “Oversquare” helps to keep the piston head vmax resonable for higher revs
- 200 rpm redline
- ~30psi actuation strength
Takeaways / Where I Learned
Takeaways / Where I Learned
- Truly think I understand engines and their concepts now
- And how they apply and interact
- Achieved something I am truly proud of that shows off my personality though my work
- Grew tremendously in the electronics and hardware side
- Mechnicaly grew in grasping manufacturing processes, assembly procedures, tolerances, and complex mates & parts
- Managed the code well and learned a little bit
Copy of IMG_3928.mov
Did I achieve my goals?
Did I achieve my goals?
- Beyond my wildest dreams!
- Rpm was far higher than I ever could have imagined I would reach
- Very proud of how it looks and functions
- Expresses me very well and is impressive looking
- Didn't really go for continuous motion for fear of breaking more crankshafts
- Worried about low pressure causing the timing to screw up and misfire but between attempts I almost never needed to adjust the “timing” so I likely could have
- Mobile electronics was huge for me in this project and helped me success greatly
- Time management failed as always but in the end I got something cool done
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