FINAL PROJECT MODEL OF VAPOR ENGINE

Group 7:
MAE 377 K44AP Thai Nguyen University of Technology www.tnut.edu.vn March 2013

Hong Minh T Nguyn Quang B

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Table of Contents
I. Problem Identification ............................................................................................................................................................ 3 II. Design Analysis....................................................................................................................................................................... 3 A. Design Machine Specifications .......................................................................................................................................... 3 B. Technical Description......................................................................................................................................................... 3 III. Individual Part Analysis ......................................................................................................................................................... 4 IV. Preliminary Hand sketch ....................................................................................................................................................... 9 V. Preliminary Bill of Materials ................................................................................................................................................ 12 VI. Working Drawings .............................................................................................................................................................. 13 VII. 3D Assembly Models ......................................................................................................................................................... 40 A. 3d Model full assembly.................................................................................................................................................... 40 B. Assembly Drawings .......................................................................................................................................................... 46 VIII. List of Standard Parts ........................................................................................................................................................ 48 IX. Cost Analysis ....................................................................................................................................................................... 49 X. Conclusion ............................................................................................................................................................................ 50 XI. Appendix ............................................................................................................................................................................. 51 A. Notice when assembly the camshaft .............................................................................................................................. 51 B. Notice about crankshaft stiffness .................................................................................................................................... 51

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I. Problem Identification
Over last 250 years, vapor (Steam) engines ushered in the American Industrial Revolution, drove the locomotives that fueled our Western Expansion, and powered ships that navigated Americas rivers and coastlines well into the 20th Century. Steam built this country, and today, steam remains the driving force behind over 60% of our nations electricity production both coal and nuclear power plants run on massive Rankine cycle steam turbines. Recent advances in steam engine technology utilizing new materials, unique designs and creative processes such as extensive heat regeneration and water lubrication have made these engines smaller, lighter, more powerful and more efficient than ever before. Today, steam engines have the potential to power cars, trucks, busses, trains and other forms of modern transportation in ways that are cleaner and less reliant on fossil fuels than current practical alternatives. What is also a reality today is that far too many government mandates are imposing, in the opinion of this author, flawed decisions, bad science and poor reasoning on the entire automobile industry and culture. These decisions negatively affect the type of cars being built, the fuels they use, and the total end cost to the consumer. We must indeed address problems of global warming, resource depletion and dependence on fossil fuels (often from unfriendly sources). It is time for such ideas to be raised and meaningful discussion to take place. That is the ultimate goal behind this paper: Design of a Model Vapor Engine.

II. Design Analysis

A. DESIGN MACHINE SPECIFICATIONS
Cylinders Arrangement type: V 90 Cylinder Diameter: 10 mm Piston Stroke: 12mm Round Piston slider without intermittent (Fully pressing type) Control stroke: 2.6 mm diameter Working pressure: 3 bars Net weight: 600 grams Dimensions: 90mm length, width 45mm below and 110 mm above the top; 90 mm height

B. TECHNICAL DESCRIPTION
The machine is intended for driving model boats up to 1.2 meters in length. When propeller diameters of up to 80mm. For smaller propeller diameters using a transmission gear is recommended. It is controlled by piston valve in the Mrklins system, without glands, resulting in a simple design and minimal friction losses. The piston rod is sealed off from the above-mentioned reasons, with an O-ring. As the piston seal is Teflon cord use. With careful design, the machine has been running smoothly with 0.3 bar air pressure. Model of a V10 twin steam engine that is thought to have propelled model ships up to 1.2 meters long with propeller diameters up to 80mm diameter. The cylinder is 10mm diameter bore, has a circular piston slide valve and an operating pressure of 3 bar. The design is based on original sketches by Mr.G.Posch. It is reasonable that, we dont have an absolute result in machine design and the description in design or manufacturing a part is not a Bible. By the best knowledge in machine elements design and a little bit luck, we got a working solution of the model vapor machine in V twin style like this. Please follow our description and notes about designing and assembling machine parts.

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III. Individual Part Analysis

All parts are manufactured and assembled with 0.1 mm tolerance. Parts that belong together must be without play and fit smoothly together. It is best if the items are made in order of part numbers and mounted. Part Number 1 Part Name Base Plate Analysis Sustains the load of all engine structures A metal solid part with many thread holes and desired hollows. Its not too difficult to manufacture this plate. Using 3 main brackets with 0.5 mm outer thickness, assembled with ball bearings to hold and keep the main shaft operating as smooth as possible. Note: all three brackets are manufactured by using glue of clamping system to stick them together and then drilling a hole to mate bearings and the shaft inside. After assembled them onto base plate, make sure the shaft can rotate easily and smoothly Picture

Main Bearing

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Main shaft and shaft components

Main shaft

Crankshaft assembly

Fly Wheel and counter weight wheel

Most V-twin engines have a single crankpin, which is shared by both connecting rods. The connecting rods may sit side-byside with offset cylinders, or they may be "fork & blade" items with cylinders in the same plane without an offset. A flywheel is a heavy body rotating about its axis. It acts as a reservoir of energy which is stored in the form of kinetic energy. Here its simple a rotating wheel which is assembled into a camshaft by the fasteners.

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Cam component (5+ 5A)

Note: the depth of the thread must be corresponding to the length of the bolt to make the shaft working (not easy to break) Convert the translating movement to rotating movement Follow design drawing and notice about the eccentricity and transmitting ratio. So in our case: 1.3X3/2

=1.95 Using a Sheet of Aluminum 2mm thickness, and an (40) aluminum round bar manufacturing base on the parameter in drawing papers
7 Camshaft assembly

Piston Rods Head

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Piston

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Piston Rod

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Cylinder Sub Assembly

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Oiler Valve Sub Assembly

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Reversal Block

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Distributor

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Protecting Lids

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Cylinder Lids

Top and bottom cylinder lids to protect the piston from the dirt. Remember to mark the holes by drilling Holding all machine parts: Cylinders, Distributor, on the right position. Helping the engine against vibration in operating

17

Supported Plates

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Connecting Parts and Clamping parts

After mounting the reversal block (part 25) on the upper cylinder support (part 24), the connecting flanges (part 28) is mounted on the cylinders and (part 29) on the reversing block. It is approximately 0.4 mm thick as heat resistant film for heat insulation between flanges or reversing block and cylinder, to clamp side of the engine

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Tubes and pipes

Conducting the flow of vapor and oil The position of the connecting lines are made of 3 mm copper pipes (see in the photos).

IV. Preliminary Hand sketch

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Rough sketch for the Crank Shaft (By Corel Draw)

Sketch for the Main Camshaft

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HAND SKETCH FOR SOME MAIN ENGINE PARTS

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V. Preliminary Bill of Materials

Item Part Number 1 BASE PLATE 2 023-A+B-CYLINDER MOUNT 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 DIN 84 - M3 x 6 02- BEARING BASE 03A1-MAIN SHAFT 03A2-MAIN SHAFT 03B-C-COUNTER WEIGHT 03B-LOCKING PIN 05A-CAM CAP 05-CAM 04-FLYWHEEL DIN 963 - M1,4 x 5 DIN 912 - M2 x 12 Cylinder Sub Assembly 024-CENTRAL SUPPORT PLATE DIN 84 - M2,5 x 5 015-DISTRIBUTOR 015A-DISTRIBUTOR LID 018- STUD DIN 934 - M2 020-ECCENTRIC SYSTEM RING 016-SHAFT CSN 02 1181 - M1,6 x 2,5 022-NUT SYSTEM 021-ECCENTRIC SHAFT 025-REVERSAL BLOCK 028-CONNECTING CYLINDER 029-CONNECTING BLOCK 030-VAPOR LINE CONNECTOR O'RING - 3 x 1 Crankshaft Sub Assembly 026A- SHAFT 026A- SHAFT CAP 026- DIRECTIONAL CONTROL VALVE 027- HANDLE CLAMP 027A- SHAFT LEVER UN 5721 - M3 OILER SUB ASSEMBLY DIN 84 - M1,6 x 5 DIN 84 - M2 x 6 023C-CYLINDER MOUNT 025A-REVERSAL BLOCK LID DIN 912 - M2 x 6 Tube 1 Tube 2 Tube 3 Tube 4 Tube 5 Unit QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 QTY Description 1 2 Supports for Cylinder block to be stable in operating 3 3 1 1 2 1 1 1 1 2 6 2 1 12 2 2 8 8 2 2 2 2 2 1 4 4 2 10 2 1 1 1 1 1 1 1 10 10 1 1 1 1 1 1 1 1 Slotted Cheese Head Screw Mass 0.035 kg 0.001 kg 0.001 kg 0.012 kg 0.005 kg 0.008 kg 0.022 kg 0.002 kg 0.001 kg 0.009 kg 0.046 kg 0.000 kg 0.000 kg 0.052 kg 0.002 kg 0.000 kg 0.029 kg 0.004 kg 0.000 kg 0.000 kg 0.004 kg 0.004 kg 0.000 kg 0.000 kg 0.001 kg 0.040 kg 0.003 kg 0.001 kg 0.002 kg 0.000 kg 0.006 kg 0.003 kg 0.002 kg 0.013 kg 0.005 kg 0.001 kg 0.001 kg 0.062 kg 0.000 kg 0.000 kg 0.001 kg 0.005 kg 0.000 kg 0.001 kg 0.001 kg 0.001 kg 0.003 kg 0.003 kg Material Aluminum-6061 Generic Steel, Mild Bronze, Soft Tin Stainless Steel Stainless Steel Steel Stainless Steel Steel Steel Steel Steel, Mild Steel, Mild Generic Steel, Mild Bronze, Soft Tin Bronze, Soft Tin Steel Steel, Mild Bronze, Soft Tin Steel Stainless Steel Copper Alloy Steel Bronze, Soft Tin Copper Alloy Copper Alloy Copper Alloy Rubber Copper Alloy Copper Alloy Copper Alloy Copper Alloy Copper Alloy Steel, Mild Steel, Mild Steel, Mild Generic Copper Alloy Steel, Mild

Countersunk Screw Cylinder Head Cap Screw

Slotted Cheese Head Screw

Hex Nut

Slotted set screws with flat point

Hexagon Domed Cap Nuts Slotted Cheese Head Screw Slotted Cheese Head Screw

Cylinder Head Cap Screw

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VI. Working Drawings

During the development of these 3d models we would often generate 2d views primarily to check the geometry of the mechanism and dimensional relationships, so we thought it might be a good idea to share some sketches of the vapor engine projects done so far.

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VII. 3D Assembly Models

The model consists of over 42 parts (excluding bolts and fittings) which we managed to build in about 3 weeks. They are successful assembled like the model below.

A. 3D MODEL FULL ASSEMBLY

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B. ASSEMBLY DRAWINGS

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VIII. List of Standard Parts

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Name of Part and Standard DIN 84 - M1,4 x 6 DIN 84 - M1,6 x 3 DIN 84 - M1,6 x 5 DIN 84 - M2 x 6 DIN 84 - M2,5 x 5 DIN 84 - M3 x 6 DIN 912 - M2 x 0,4 x 6 x 5 DIN 912 - M2 x 0,4 x 12 x 11 DIN 913 - M2 x 8 DIN 934 - M2 x 0,4 DIN 963 - M1,4 x 5 O'RING - 1.5 x 1 O'RING - 3 x 1 O'RING - 5 x 1.5 UN 5721 - M3 - 0,5 CSN 02 1181 - M1,6 x 2,5 Quantity 4 6 10 10 12 3 1 6 2 8 2 0 10 0 1 2 Description Slotted Cheese Head Screw Slotted Cheese Head Screw Slotted Cheese Head Screw Slotted Cheese Head Screw Slotted Cheese Head Screw Slotted Cheese Head Screw Cylinder Head Cap Screw Cylinder Head Cap Screw Hexagon Socket Set Screw Hex Nut Countersunk Screw Rubber sealing Rubber sealing Rubber sealing Hexagon Domed Cap Nuts Slotted set screws with flat point

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IX. Cost Analysis

The total projected cost for manufacturing of this product and distributing it to venders is projected to be $495. The breakdown of the costs is given below:

LABOR # Hour s Technical Administrative Professional Licensed/Certified Total Labor MATERIALS # Units Aluminum 6061-T6511 Bare Extruded Rectangle 44.45 mm x 63.5 mm Cut to: 10-12" random length Mild Steel 1018 Cold Finish Rectangle 9.52 mm x 50.8 mm Cut to: 12" & Mild Steel 1018 Cold Finish Round 15.88 mm Cut to: 12" Stainless T-303 Annealed HRAP Rectangle 31.75 mm x 152.4 mm. Cut to: 10-12" random length Stainless T-13-8 Centerless Ground Round 15.88 mm Cut to: 12" Brass 360 H02 Extruded Rectangle 6.35 mm x 50.8 mm Cut to: 10-12" random length & Brass 360 H02 Extruded Round 11.11 mm Cut to: 10-12" random length X Price/Uni t $ 22.02 = Total Cost $ 22.02 24 24 24 24 X X X X X Hourly Rate $ 2.00 $ 1.50 $ 4.00 $ = = = = = Total Labor Cost $ 48.00 $ 36.00 $ 96.00 $ $ 180.00

Aluminum-6061

Steel, Mild

$ 9.60

$ 9.60

Stainless Steel

$ 360.60

$ 360.60

Bronze, Soft Tin

$ 23.45

$ 23.45

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Steel

Copper Alloy

Mild Steel A36 Hot Rolled Rectangle 15.88 mm x 50.8 mm Cut to: 12" Copper 110 H04 Rectangle 6.35 mm x 50.8 mm Cut to: 10-12" random length & Copper 110 H04 Round 12.7 mm Cut to: 12"

$ 8.92

$ 8.92

$ 31.16

$ 31.16

Total Materials OVERHEAD

$ 455.75

Insurance Work Comp Insurance Project Specific Insurance Prop. & Casualty Supervision Sales Facilities Delivery Travel Tax Total Overhead

Total Cost $ $ $ $ $ 63.58 $ 20.00 $ $ $ 31.79 $ 115.36 $ 751.11

TOTAL COST

ADDITIONAL COMMENTS:

X. Conclusion
The design is actually quite complex and there were some issues with dimensional accuracy and match hole diameters. All the parts in this design are modelled to an accuracy of 0.01mm with the majority now having fully detailed working drawings dimensioned with both mm and inch sizes.. We understand that the final product of this model work exceptionally well.

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XI. Appendix
A. NOTICE WHEN ASSEMBLY THE CAMSHAFT
Follow this drawing:

B. NOTICE ABOUT CRANKSHAFT STIFFNESS

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