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UNIVERSITY OF BOLTON SCHOOL OF THE BUILT ENVIRONMENT AND ENGINEERING BENG (HONS) AUTOMOBILE ENGINEERING SEMESTER 2 EXAMINATIONS 2008/2009 POWER TRAIN TECHNOLOGY 3 MODULE NO: ATT3012

Date: Monday, 1 June 2009

Time: 2.00 5.00 p.m.

INSTRUCTIONS TO CANDIDATES:

There are SIX questions on this paper. Answer FOUR questions All questions are worth 25 marks each. Air density = 1.2 kg/m3 g = 9.81 m/s2 Density of diesel fuel = 840 kg/m3 Graph paper is available

Page 2 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

1.

A truck fitted with a box-type body has been designed to operate at a maximum laden weight of 12000 kg. It is fitted with a six-cylinder turbocharged diesel engine which has the performance map shown in Fig Q1 (maximum power output of 134 kW at 2600 rpm). Other data for the truck is as follows: Drag coefficient = Rolling resistance coefficient = Vehicle width = Vehicle height = Tyre rolling radius = Gearbox efficiency = Axle efficiency = Axle ratio = th Top gear (6 ) ratio = (a) 0.76 0.01 2.4m 3.6m 0.47m 96% 96% 5.4:1 0.8:1

Calculate the power required, at the wheels of the laden truck on a level road, to operate at 100 km/h. (5 marks) A set of aerodynamic add-on parts are fitted to the truck, which lowers the drag coefficient to 0.5. Calculate the power required at the wheels of the truck to operate at 100 km/h on a level road, with the aerodynamic add-ons fitted. (3 marks) Estimate the fuel consumption, in /100 km, of the standard truck at 100 km/h on a level road, in top gear. (8 marks) For the low drag coefficient version of the truck, identify the axle ratio which would give the best fuel economy in top gear at 100 km/h. Comment on TWO ways in which other aspects of the trucks performance would be affected by changing the axle ratio. (9 marks)

(b)

(c)

(d)

N.B. Include any workings which you make on Fig Q1 with your answer book. Total 25 marks

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Page 3 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

2.

A college is to compete in an electric vehicle competition for small one-seater cars powered by a 12 volt car battery. The aim of the competition is to complete most laps over a fixed 1 km track over 4 hours, with 1 battery change allowed. The track consists of a 300 m long level road, followed by a 10% uphill gradient which is 100 m long, then followed by a 400 m long level section, and finally a 5% descent for 200 m. The specification of the car is as follows: Mass (including driver and battery) = 200 kg Width = 450 mm, Height = 800 mm Drag coefficient = 0.4 Rolling resistance coefficient = 0.01 Maximum battery charge = 90% of full capacity Minimum battery charge for operation = 30% Electric motor efficiency = 0.95 Transmission efficiency = 0.98 Battery capacity = 40 Ah (a) Calculate the power output of the electric motor you would recommend to enable the vehicle to climb the hill part of the circuit and still maintain a suitable pace to win the competition (NB. the team aim to complete 44 laps of the track in 4 hours, and will take 5 minutes to change batteries). (Assume speed of 2 m/s on hill). (10 marks) The team have calculated that a minimum speed of 3.33 m/s is necessary on the level parts of the circuit, in order to achieve 44 laps. Estimate if this is correct in order to complete the competition using the two batteries given. (NB no energy is consumed on the down hill section). (15 marks)

(b)

Total 25 marks

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Page 4 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

3.

(a)

A new joint venture between British and French van manufacturers is aimed at producing a new range of vans with a range of laden masses of 2000 kg to 3500 kg. In order to predict the required performance of this new vehicle range, a competitors van is being used as a benchmark, but not all of the required information is easily available. The company need to set a target rolling resistance coefficient, Cr, for the van based on the following performance data for their competitor. Acceleration from 60 km/h to 100 km/h on a level road = 19.2 s Laden mass of van = 2760 kg Axle ratio = 3.154:1, Gear ratio = 1:1 Body width = 2.05 m, Body height = 2.54 m Overall transmission efficency = 0.92 Tyre rolling radius = 0.33 m Drag coefficient = 0.39 Engine torque = 285 Nm, from 1400 rpm to 2700 rpm. From the above information, calculate the rolling resistance coefficient of the competitors van. (18 marks)

(b)

The competitors van is also tested for fuel consumption at 100 km/h on a level road, and achieves 12 /100 km under these conditions, in the same gear as in part (a). Calculate the specific fuel consumption of the engine at these conditions, in g/kWh. (7 marks) Total 25 marks

4.

(a)

The overall efficiency of a vehicle is affected by losses due to factors such as transmission losses and tyre losses. Describe, in detail : (i) (ii) (iii) How transmission (gearbox and final drive) losses occur (3 marks) How rolling resistance losses at the tyre occur (3 marks) How the transmission losses and rolling resistance losses for a four-wheel drive vehicle would differ from a two-wheel drive vehicle. (2 marks)

Question 4 continued over

Page 5 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

Question 4 continued

(b)

A new four-wheel drive vehicle has been developed for both off-road and on-road use. Fig Q4 shows the saw tooth diagram for the vehicle in all 5 gears. The final drive ratio of the transmission is 4.2:1, and the gearbox ratios are : 1st 2nd 3rd 4th 5th Calculate : (i) (ii) (iii) The overall ratio spread of the gearbox The overall transmission ratio in 1st gear The rolling radius of the tyres (2 marks) (2 marks) (4 marks) 3.25:1 1.89:1 1.22:1 0.85:1 0.65:1

(c)

If the vehicles maximum speed (Fig Q4) is 166km/h at an engine speed of 5500 rpm, calculate the rolling resistance coefficient of the vehicle using the following data : Engine Power at 5500 rpm = 89 kW Transmission efficiency = 91% Drag coefficient = 0.4 Vehicle mass = 1520kg Frontal area of vehicle = 2.85m2

(9 marks) Total 25 marks

Q5

(a)

The overall efficiency of an engine is dependent upon a number of factors associated with sub-systems of the engine. Outline, with the use of diagrams, your understanding of the following terms : (i) (ii) (iii) (iv) Mechanical efficiency of an engine (2 marks) Volumetric efficiency of an engine (2 marks) Indicated thermal efficiency of an engine (2 marks) All of the above 3 efficiencies can be calculated using experimental or computer modelling techniques. Show how the 3 efficiencies could be combined to give the overall efficiency (brake thermal efficiency) of the engine. (2 marks) Question 5 continued over

Page 6 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

Question 5 continued (b) Describe THREE methods of measuring engine friction, outlining the advantages and disadvantages of each method. Use diagrams to assist your answers. (9 marks) A 2-litre, 5-cylinder turbocharged petrol engine produces a maximum power of 160 kW at a speed of 6500 rpm. A Willans line test is carried out on the engine at 6500 rpm and 2500 rpm, giving the results below : 6500 rpm Power (kW) Fuel consumed (kg/h) 100 24.0 60 15.8 40 12.8 20 10.0 10 8.5 2500 rpm Power (km) Fuel consumed (kg/h) 60 11.8 50 10.1 40 8.6 30 7.0 20 5.7

(c)

Using the graph paper provided, plot the Willans lines for both speeds and estimate the engines friction power at 2500 rpm and 6500 rpm. (8 marks) Total 25 marks

Q6

(a)

A modern engine lubricant would contain the following chemical additives : Viscosity index improver, anti-oxidant, E.P. additive, friction modifier. Explain the purpose of each of the above additives. (4 marks)

(b)

Within an engine, the FOUR modes of lubrication (boundary, mixed, elasto-hydrodynamic and hydrodynamic), are all likely to be seen in different parts of the engine, and at different operating conditions. Explain, briefly, the FOUR modes of lubrication in terms of oil film thickness and mechanism of lubrication. (8 marks) Briefly describe ONE part of an engine where each of the above FOUR modes of lubrication would operate. (4 marks)

Question 6 continued over

Page 7 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

Question 6 continued

(c)

An engine cam has a tip radius of 30mm, a width of 12mm and operates against a flat cam follower. Using elasto-hydrodynamic theory, calculate the minimum oil film thickness between the cam and the follower for the following conditions : Sliding speed of cam = 5 m/s Oil viscosity = 0.2 Ns/m2 Oil pressure-viscosity coefficient = 2 x 10-8 m2/N Youngs modulii for cam and follower = 230 GN/m 2 Poissons ratio for cam and follower = 0.3 Maximum force on cam, from valve spring = 150 N Use the equation hmin normal meaning.
2.65 G.54 U .7 R where G, U, W, R have their W .13 (9 marks)

Total 25 marks

END OF QUESTIONS

Page 8 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

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Page 9 of 9 School of the Built Environment and Engineering BEng (Hons) Automobile Engineering Semester 2 Examination 2008/2009 Power Train Technology 3 Module No. ATT3012

Fig. Q1