Engineering a System: A Real World Application

Cody Seidler Written for Freshman and Junior Mechanical Engineers October 18, 2012

Audience and Purpose

This document will help inform new engineers about physical systems linked to classes they will ultimately take. It will take a unique system (such as a dirt bike), break the system into sub-parts, and analyze each sub-part to identify which potential class topics explain why and how that sub-part works. It will then look at the system overall to analyze the dynamics of input (throttle) to output (torque). The documents end goal is to show the engineers that what they learn can be applied to a complex real world system as well as broaden their understanding of class topics.

Introduction
A system can be defined as a complexity of parts working together as a whole to perform a function. One such system is a single cylinder 2-stroke dirt bike. The bike is a complex system that can be divided into five subsystems: Throttle, carburetor, engine, transmission, and output torque on rear wheel. This system has the input of the throttle and the output of torque, which is the primary function of this particular system. As each part is understood different course topics will be presented that can be used to explain (mathematically or theoretically) how the part works.

Throttle Input

Carburetor

2-Stroke Engine

Torque Output

Transmission

User Input: The Throttle

In order for a system to have an output it must have an input. The input of this system starts with the throttle. It is here at the throttle that the user has control and stability of the system and its total output. The throttle works as follows:

1) The throttle tube is twisted by the user

2) The throttle cable is attached to the throttle tube and is twisted around the handle bar

3) The throttle cable is pulled up the cable tube

Relevant Courses
The fundamental workings of the throttle can be described using material from courses such as Strength of Materials or Mechanical Component Design. Using knowledge from these classes it would be possible or necessary to find, say, the stress and strain of the throttle cable. If the cable is not designed correctly it can possibly fail during use from excessive stress. It is also of normal occurrence for the cable to stretch over time from average use. This elongation can also be described using concepts learned from these courses.

Collecting Energy: The Carburetor

In order for a system to output energy it must first collect energy. The way in which a dirt bike system collects the necessary energy is via the carburetor. This energy is a combination of air and gasoline mixed at an optimum ratio in the amount determined by the users throttle input. The carburetor works as follows:

1) The throttle cable is pulled

2) The cable is attached to the main valve of the carburetor and pulls it open 3) Air is let in from the inlet side of the carburetor 4) The air is passed by the main valve and experiences a decrease in area 5) The decrease in area causes a pressure drop which pulls gasoline from the reservoir at the bottom of the carburetor 6) The gas and air mix and are sent from the carburetor via the outlet side

Relevant Courses
The primary course that describes a carburetors operation is Fluid Mechanics. It is in this class that fluid motion is characterized and described. These mechanics can describe how gasoline is pulled from the reservoir due to the reduction of cross sectional area the air passes through, an effect known as venture flow.

Converting Energy: The Engine

A system can never create more energy than it collects/uses. However it is relatively simple to convert energy to different forms, one such method is the engine. The dirt bike engine can convert the chemical energy stored in the air/gas mixture into the thermal energy of combustion. A single cylinder 2-stroke engine is one of the simplest engines; it has only three main moving parts. This is opposed to the more familiar 4-stroke engine (such as a car) which uses valves and cams. This engine converts energy as follows:

1) The air/gas mixture is sent from the outlet side of the carburetor 2) The piston descends from the previous combustion and allows the air/gas mixture to fill the cylinder head 3) The piston ascends and pressurizes the air/gas mixture 4) The spark plug ignites the mixture which releases the chemical energy causing a combustion 5) The combustion pushes the piston down and then goes back to step 2

Relevant Courses
The fundamentals of the engine can be described using Thermodynamics. The first law of thermodynamics will explain that this system will never create more energy than held in the air/gas mixture. The second law of thermodynamics will show that this system will never be 100% efficient, that is, this system cannot convert all the chemical energy held in the air/gas mixture into mechanical energy. This is due to the fact that all processes produce heat, which uses some of the converted energy.

Controlling Energy: The Transmission

In the previous step the engine converted energy in just two cycles of the piston (hence 2-stroke). However in reality it could be doing this thousands of times in a minute. The question is: how is all this energy controlled? The answer is the transmission. The transmission is a complex series of gears and clutches that allows the user to control the speed/power ratio of the piston to the output torque. It applies the load on the system so the system doesnt run out of control and ultimately explode. An example of such a scenario is putting a car in neutral gear and holding the petal to the floor until something breaks. However thanks to a transmission its possible to supply an input and not break the system. Put very simply the transmission works as follows: 1) The piston descends

2) As the piston descends it turns the crank shaft

3) The clutch (not shown but connects the drive and crank shafts) turns the drive shaft

4) The drive shaft is connected to the final drive through a series of gears

5) The final drive is connected to the front sprocket

6) The front sprocket drives the chain which ultimately turns the rear wheel

Relevant Courses
Mechanical Component Design and Lubrications are two classes which are required to understand the principles of a transmission. Its essential that one knows and understands wear and fatigue, both of which are taught in mechanical design. With the constant contact between gears, the design must be suitable to achieve a desired lift. Also in order to achieve this life lubrication is vital. Without efficient lubrication the gears will over heat and melt, causing the system to fail.

Does it Apply to You?

Yes, this does apply to you as a new engineer. When looking at a system it is important to understand each aspect or subsystem. Each one could be a potential application in such classes as: Mechanical Component Design Strength of Materials Fluid Mechanics Thermodynamics Lubrications

Modeling of dynamic systems is one of the last classes you will take and involves looking at the system as a whole. In order to understand the whole system and describe it mathematically you must understand the parts. Therefore each class taken will be applicable to many different real world scenarios and systems, it does apply to you.

Works Cited In Order of Appearance

Full dirtbike, Eurocarsdiary.com, 2012 http://www.eurocarsdiary.com/wp-content/uploads/2012/02/dirt-bike-3.jpg Throttle: Added arrows and numbers, giobikes.com http://www.giobikes.com/5/131_21_0008.JPG Side Carburetor : Added arrows, auctiva.com http://img.auctiva.com/imgdata/4/7/8/9/5/1/webimg/493157591_o.jpg 2-stroke Combustion Engine: Added arrows, pilotfriend.com http://www.pilotfriend.com/training/flight_training/tech/images/8.jpg KTM Transmission: Added arrows, motorecylcer.com http://www.motorecycler.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27 136e95/B/2/B230_001.JPG Dirtbike Rear Wheel: Added arrows, dreamstime.com http://thumbs.dreamstime.com/thumblarge_306/12202670228C337P.jpg Front view Carburetor: Added arrows, photobucket.com http://media.photobucket.com/image/recent/oemcycle/KX500%2520KAWASAKI%25202000/CARBURET OR/carb.jpg All images found from google images