Today we had to present stage 3 of our project. When we entered class there was only 6 of us. Jal and I were the only group that was there and me and him were not keen on presenting first so we had to wait for about half an hour before finally someone decided to present first. For the first time Simon and Vadim were not the first to present their work which makes me feel a bit better.
Also this time I was really happy with our progress in the technology project. There was plenty to present with the practical testing that we had done. I was really happy with what he had presented after we had finished as I believed that we had made some really good progress over the other groups that had presented.
At the end of the presentation Anura questioned us as to whether or not we thought the project was viable or not. I immediately said no as the highest pressure achieved was 0.5 psi. And most exhaust brakes operate at around 30 - 60 psi. For this reason I said no. Anura then said we should calculate backwards and workout whether that pressure achieved would actually slow the piston down or not. This is a good idea and it would be good to see what becomes of these calculations. I still believe however after our practical testing that the exhaust brake on small diesel engines is going to be unviable. Considering the cost of the unit compared to what it can achieve for engine braking in diesel engines.
Wednesday, 30 October 2013
Technology Project Class 11
Today there was no official class for technology project. However Jal and I still went into uni as today finally the technician had put in the valve on the Mercedes common rail diesel engine. So is that we could get some pressure readings done for the exhaust system in the engine and see how it works and how the exhaust brake may affect these readings.
First we did tests at varying RPM's to get different pressure readings across the rev range without an exhaust brake. Then we did tests with the exhaust brake applied all the time and noticed a large increase in exhaust pressure on the manometer. Finally we did tests with the exhaust brake applied at engine overrun conditions and noticed the largest pressure readings which is good to see our projects concept actually works.
First we did tests at varying RPM's to get different pressure readings across the rev range without an exhaust brake. Then we did tests with the exhaust brake applied all the time and noticed a large increase in exhaust pressure on the manometer. Finally we did tests with the exhaust brake applied at engine overrun conditions and noticed the largest pressure readings which is good to see our projects concept actually works.
Technology Project Class 10
Today we had our second stage presentation on our progress on our technology project the retro fit exhaust brake. Once again I feel as if we have not achieved enough and that we are not making particularly good progress. And once again Simon and Vadim presented their project first. In comparison to their progress we have done nothing. I am hoping to some progress this week.
On thursday we met with our technical advisor, Anura and he said to use that we should do a hardness test on the exhaust brake butterfly valve and shaft which were he had kindly sourced and supplied to us for free. So we went to see Jone the materials lecturer who did not know how to use the hardness tester. So he told us to see Anura who wound up knowing how to use and showed us. He told us about the different hardness testing ways which go from hardness rockwell A through to hardness rockwell G.
The next part really interested me, Anura was able to get one of the technicians to fit a valve in the back of the exhaust pipe behind the turbo so is that we could use a manometer to measure the pressure behind the turbo. So I am hoping that the technician can do this so we can get some more practical testing done, rather than all our work being theoretical.
On thursday we met with our technical advisor, Anura and he said to use that we should do a hardness test on the exhaust brake butterfly valve and shaft which were he had kindly sourced and supplied to us for free. So we went to see Jone the materials lecturer who did not know how to use the hardness tester. So he told us to see Anura who wound up knowing how to use and showed us. He told us about the different hardness testing ways which go from hardness rockwell A through to hardness rockwell G.
The next part really interested me, Anura was able to get one of the technicians to fit a valve in the back of the exhaust pipe behind the turbo so is that we could use a manometer to measure the pressure behind the turbo. So I am hoping that the technician can do this so we can get some more practical testing done, rather than all our work being theoretical.
Tuesday, 24 September 2013
Technology Project Class 9
I am starting to get concerned with Jal as he does not want to put in 100% effort and seems to want to prioritize doing something menial to doing our project. In these 9 weeks we have only seen Anura 3 times. I keep telling him that we now have to see him twice a week but he always winds up being 'Busy' I'm not concerned about the project not being finished. I am however concerned about the amount of meetings that we need to have with Anura is very slack.
There was no need to go to class today so for that reason neither me nor Jal went to uni. I had decided to do some work for the project today but having some complications with my car meant nothing was achieved. I do feel as if my effort into this class is suffering as well. These holidays I really need to pull finger and get some good work done, there are to be no excuses this time.
There was no need to go to class today so for that reason neither me nor Jal went to uni. I had decided to do some work for the project today but having some complications with my car meant nothing was achieved. I do feel as if my effort into this class is suffering as well. These holidays I really need to pull finger and get some good work done, there are to be no excuses this time.
Technology Project Class 8
For today's class there was the second group of people doing their presentations that did not do their presentations last week. This meant that there was no real need for Jal and I to go to class.
However we had been slacking somewhat to seeing Anura on our progress for the technology project. For this reason I pushed for the decision to go and see him today. Once again we had encountered a few problems with cooling the exhaust brake. However Anura told us that since there is no cooling system on standard exhaust brakes then this should not be a problem for our exhaust brake. This certainly makes the design concept on solid works much easier for us.
The other issue that we discussed was that Gerry told us that the turbo's oil seals would not be capable of handling the exhaust back pressure. However since these seals are made of aluminium alloys they are in-fact very strong. Anura said that the issue of back pressure on the oil seals is not actually and issue at all which is certainly relieving.
Lastly Anura told us that we should have some tangible data to use for our project. For this reason he said we can do exhaust pressure testing on the Mercedes diesel engine that is located at building 100. This will certainly make doing our calculations much easier than before as we now are able to have a starting point.
However we had been slacking somewhat to seeing Anura on our progress for the technology project. For this reason I pushed for the decision to go and see him today. Once again we had encountered a few problems with cooling the exhaust brake. However Anura told us that since there is no cooling system on standard exhaust brakes then this should not be a problem for our exhaust brake. This certainly makes the design concept on solid works much easier for us.
The other issue that we discussed was that Gerry told us that the turbo's oil seals would not be capable of handling the exhaust back pressure. However since these seals are made of aluminium alloys they are in-fact very strong. Anura said that the issue of back pressure on the oil seals is not actually and issue at all which is certainly relieving.
Lastly Anura told us that we should have some tangible data to use for our project. For this reason he said we can do exhaust pressure testing on the Mercedes diesel engine that is located at building 100. This will certainly make doing our calculations much easier than before as we now are able to have a starting point.
Wednesday, 4 September 2013
Technology Project Class 7
Today we had to present our second presentation for technology project and the progress that we have made with it. The first group that went up was Simon and Vadim and after their presentation on their ECU and the progress that they have made I felt as if we hadnt made enough of an effort.
However after a few more people had presented I had concluded that our progress was much the same to the rest of the class. It seemed as though Jal was quite a bit more nervous than I was about the presentation and at a few points ran out of ideas to say so I had to jump in to complete what he was trying to say. Surprisingly I wasnt as nervous as I first thought I would be.
After our presentation we had a few more curve balls thrown at us for our exhaust brake project. The first curve ball stating the complete opposite of what I had researched. Gerry told us that if the exhaust brake is located behind the turbo then the turbo will spool up faster and faster and with little oil being supplied will actually burst. He likened this comparison to a vacuum cleaner and having your hand placed over the nozzle it causes the motor to spin faster.
Other issues included heat dissipation, a much larger area for exhaust gases to by pass than I first thought and a safety system that makes sure that the exhaust flap does not fully close in case of failure so is that the car is still drive-able.
Now that I have solid works on my computer Jal and I can finally begin the design process of the exhaust brake and start doing calculations to either prove or disprove our idea from working.
Anura was not in class today so we could not go and see him to review what we have done so far so we will have to see him on Thursday so he can help us decide on whether or not we are on the right track or not. And help us decide what step to take from here.
However after a few more people had presented I had concluded that our progress was much the same to the rest of the class. It seemed as though Jal was quite a bit more nervous than I was about the presentation and at a few points ran out of ideas to say so I had to jump in to complete what he was trying to say. Surprisingly I wasnt as nervous as I first thought I would be.
After our presentation we had a few more curve balls thrown at us for our exhaust brake project. The first curve ball stating the complete opposite of what I had researched. Gerry told us that if the exhaust brake is located behind the turbo then the turbo will spool up faster and faster and with little oil being supplied will actually burst. He likened this comparison to a vacuum cleaner and having your hand placed over the nozzle it causes the motor to spin faster.
Other issues included heat dissipation, a much larger area for exhaust gases to by pass than I first thought and a safety system that makes sure that the exhaust flap does not fully close in case of failure so is that the car is still drive-able.
Now that I have solid works on my computer Jal and I can finally begin the design process of the exhaust brake and start doing calculations to either prove or disprove our idea from working.
Anura was not in class today so we could not go and see him to review what we have done so far so we will have to see him on Thursday so he can help us decide on whether or not we are on the right track or not. And help us decide what step to take from here.
Technology Project Class 6
For our sixth class Jal and I decided we would be far more productive at home so we did not come into class with the plan of seeing our technical advisor on thursday. We worked on our presentation for next weeks class, trying to gather information to try and see whether or not this idea of ours would actually work.
With the brief amounts of information we have gathered so far I am somewhat skeptical of our project simply because it seems as though the exhaust pressures achieved would be far to great and the variety among manufacturers makes it hard to set a safe point. Or a point where all engines benefit from the exhaust brake without issues occurring.
I feel that with New Zealands small motor fleet our exhaust brake may not be effective enough to be viable. Other retro fit kits out there are used on large diesel motors which are 3 litres and greater in capacity with atleast 6 cylinders. In New Zealand we have many 2 litre 4 cylinder diesel engines, so is there going to be enough exhaust pressure created? It is something we will have to investigate.
As for the progress of our first presentation I felt as if we didnt have much and I would have loved to have solid works on my computer so is that I can start conceptualizing ideas for how our exhaust brake will look. For now I added in a very simple sketch on how it will look, but will most likely evolve significantly from my first primitave sketches.
With the brief amounts of information we have gathered so far I am somewhat skeptical of our project simply because it seems as though the exhaust pressures achieved would be far to great and the variety among manufacturers makes it hard to set a safe point. Or a point where all engines benefit from the exhaust brake without issues occurring.
I feel that with New Zealands small motor fleet our exhaust brake may not be effective enough to be viable. Other retro fit kits out there are used on large diesel motors which are 3 litres and greater in capacity with atleast 6 cylinders. In New Zealand we have many 2 litre 4 cylinder diesel engines, so is there going to be enough exhaust pressure created? It is something we will have to investigate.
As for the progress of our first presentation I felt as if we didnt have much and I would have loved to have solid works on my computer so is that I can start conceptualizing ideas for how our exhaust brake will look. For now I added in a very simple sketch on how it will look, but will most likely evolve significantly from my first primitave sketches.
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