Week Twelve

This week we had our third project presentation and I am pleased to say that it went well. We were able to present the class with tangible practical results which lets be honest they were waiting for. We proved to the class that our project woks as a concept. However we had done pressure calculation from our results and found out that the maximum pressure achieved by us was 0.5 PSI. This is disappointing figure as we were expecting figures of about 30 - 60 PSI.

Doing some thinking I realized that we had used our exhaust flap and blocked the end of the exhaust (as we couldn't really block it behind the turbo). Now exhaust pressure behind the turbo would be much higher compared to the pressure at the end of the exhaust. This theory is based on pressure drops. Since the exhaust air travels through a series of bends and restrictions (CAT and Mufflers) exhaust pressure drops. I still believe that if we were to block the exhaust behind the turbo we would achieve the high pressure readings which we are looking for.

Week Eleven

This week  we had no official class as such but me and Richard did go to uni to do our practical tests on the common rail diesel engine. The technician has finished installing the prob on it so we put our boots on, met up with Anura and went to the engine. Before we start practical it is important to have a plan and inspect the engine we are testing with. We discovered that the engine we are using is having a variable vane turbo charger. This means that turbo pressure and flow changes in relation to engine rpm and load.

We did pressure tests at 1000 RPM to 3000 RPM while having 500 RPM intervals. We tested the exhaust pressure with a exhaust brake and without a exhaust brake. I am happy to say that after testing we have proved that out concept works! Now it is time for some calculations.

Week Ten

I have mixed feelings regarding this week. Firstly our second stage presentation was due in. Although we had some good theory information to present; the lack of practical work still made me feel as if we haven't progressed much. I believe practical is an important part of this project, and yet so far we haven't done any. But things were about to change.

We met up with Anura on Thursday and he suggested that we do a metal hardness test on an existing exhaust brake flap. He kindly sourced one out for us from a Mercedes Benz truck. Materials being Jone's subject we went to him for guidance on how to do a hardness test. To our surprise Jone seemed clue less on how to use the hardness tester. He suggested that we take is back to Anura and let him guide us. I am really suspicious as to if Jone is dumb or just plain lazy. Anyways Anura guided us through the test and we finally had some practical work done.

As mentioned on an earlier weeks post, we have a Mercedes Benz common rail diesel engine to use. We had a technician look at it an install a prob behind the turbo exhaust housing. This meant that we were now able to use a manometer and do some pressure testing. Id say this has been a good week!  

Week Nine

Nothing really to mention here. Project progress is rather slow and I know I am slacking behind. Guess I need to stop prioritizing other thing and take this project more seriously. Time is running out and we are just stagnating. Come on Jal what are you doing!!!!!

Week Eight

This week we had a second group of people doing their presentations. In short there was no need for us to go to class today. Me and Richard went into uni today to meet up with Anura and discuss the issues regarding our project. 

We brought forwards all of the issues being raised in class the previous week and to our surprise Anura discarded all of them. Firstly the turbo spool up effect. Anura told us that a diesel turbo has seals made out of aluminum alloy and are rather very strong. Thus upon the incident of a turbo spool there would be no damage caused to the turbocharger. The second issue we had was regarding heat dissipation. For this issue Anura brought our attention to the current sytems running in trucks. He mentioned to us that they do not require heat dissipation so neither should our exhaust brake. 

Lastly Anura suggested us to have some tangible information (practical work). He mentioned to us that Unitec has a common rail Mercedes Benz diesel engine which would be perfect for our project. We could use this engine and do exhaust pressure testing. These results would certainly make doing our calculations much easier. Also I believe doing practical work is far better than doing research as by doing this we physically learn and see where we are in regards to our issue and our project.  

Week Seven

This week we had another presentation due and I must say I was quite nervous about it. I believe this is due to my lack of input within our project. I have recently experienced a death in the family. This has somewhat demotivated me to work. But like they say the show must go on. I would like to mention my partner Richard as he was the star with our  presentation. He helped me out when I got stuck and really pulled my weight along with him. 

As normal we let the class ask us any concerns they have in regards to our project. Surprisingly this time it was Gerry who saw a possible flaw with our design. He told us that if we put our exhaust brake behind the turbo then we would be spooling up the turbo more. To further explain his point he linked his concern with a vacuum cleaner. What happens to a vacuum cleaner when u block the opening? It speeds up right. He suggested that by placing our exhaust brake behind the turbo we would cause serious damage to the turbo.

Other issues pointed out by the class were heat dissipation, the size of the area of the exhaust bypass and a possible fail safe system. Unfortunately Anura was not present in the class today to give us feedback upon what we have done. No matter tho we have an appointment with him on Thursday so we will discuss it then.

I would like to leave here today with some good news. Richard finally has solid works onto his computer. This means we can finally get started onto designing our exhaust brake virtually. 

Week Six

This week we decided to not go into class and work on our project at home. We are still in the research area regarding to the project. I must say it is still very hard to find good information regarding the project. Yes there are kits available out there but it seems to me that the companies which develop those kits are keeping all of the information to themselves.

Within our research we found out that the retro fit exhaust brakes were fitted to vehicles with relatively large diesel engines. For example a cummis 3litre 6cylinder diesel engine. New Zealand being a small nation has a small fleet of vehicles. We seem to like our small diesel engines and not many of us have large diesel engines. Will our project work for small diesel engines too? Will small diesel engines need an exhaust brake kit? So many question with no means to answers them. Looks like we need to discuss these points with Anura.

Lastly we have decided that our project will be virtual therefore we require the use of solid-works. Quest for finding someone with solid-works has begun.  

Week Five

Week five is here and we start this week with our presentation. I must say I always get nervous before presenting. After presenting our idea to the class we gave them a chance to reflect back and ask us their concerns regarding our project. One of the main concerns was the pressure put onto the piston as we apply the exhaust brake. I must say that I hadn't though about this yet. This corncern was later discusssed with our technical adviser and he told us that the piston upon combustion experiences far greater pressures than the pressure it would experience upon exhaust braking. 

Other issue raised by the class were relatively small. For example we were asked if we were to create a exhaust bypass area as you cannot block an exhaust 100%. Such issues are to be rectified upon further progress of the project. I must say the issues and concerns raised by the class was good food for thought. Taking all aspects of the day into consideration I feel our presentation went well.

Later we met with Anura (our technical adviser) and we discussed upon further progress. Anura gave us some good research ideas. He also mentioned to us that we should stop fuel injection upon the engagement of the exhaust brake. We are to do further research as to why. All in all this was a good week and I must say our project is far more involved than I first thought.

Week Four

Although we had an idea in our minds, we discovered that it is extremely hard to do any research for our idea. This is week four, which means that our literature review is due in along with a power point presentation on what our project is going to be. I know we are lacing behind at this point as I see other groups are presenting some good ideas in front of the class. The issue here is that we are willing to do the work but we are just not finding the proper path. 

We decided to hang back and wait till the first break so that we could speak to a lecturer about the issues we are facing. Upon the arrival of the break I decided to speak to Roman and ask for an extension. I explained our situation and he gave us a weeks extension. This was good news. We then decided to speak to Anura about our idea and ask him what he though about it. To our surprise he was very encouraging and told us that it was a good idea.  He mentioned that our project would only work on vehicles with a manual transmission or automatics with a tiptronic or a low gear function. This is due to the torque convertor function of an automatic gearbox.

We discussed the issues we were facing regarding our research and he suggested few starting points for us. Seeing as we did not have a technical adviser yet we decided to ask Anura if he was willing to take us under his wing. He said yes! Finally we have a project idea, a technical adviser and a place to start our research.  

Week Three

We start this week pretty much from where we left off in the previous week.  STILL NO IDEA FOR A PROJECT! This is worrying as we have to present our issue and solution for a technological project in week four. How are we going to do that if we do not yet have a project idea.

After doing a bit of thinking I realized that Ive always wanted to try and incorporate an exhaust brake into petrol engines. My idea is inspired by the exhaust brakes used within trucks.These brakes help the trucks maintain control under deceleration and also assist in slowing down and stopping the truck. I discussed my idea with my partner Richard and we both felt that it was an good idea.

However after doing some research my partner Richard told me that my idea of an exhaust brake within petrol engines would not be viable. This was discouraging news. I decided to ask Anura who is my EMS lecturer about why it would not work. He told me well this is simple. Petrol engines are air controlled; therefore under overrun conditions the exhaust gasses would be very low to create a backwards pressure. Diesel engines on the other hand are fuel controlled.

Me and Richard took that information and decided to create a retro fit exhaust brake for small diesel engines such as SUVs and pickup trucks. Doing further research we found that such kits are already available but they are vacuum controlled. To make ours unique, we decided to make our kit electrically controlled.

Week Two

We start the week with good news! After a weekend of thinking about an issue and what to do; Richard my group partner came up with the idea of a solenoid controlled water pump. The theory behind the idea/issue is as following.

We all know that a cold engine is an inefficient engine; as its air/fuel mixture is rich in order to create combustion. Rich mixture also increases emissions. The water pump always circulates coolant thus increasing the engine warm up period. So to resolve this issue we though of disconnecting the water pump while the engine is cold and warming up and have it re-connect when the engine reaches a certain temperature. The water ump would be solenoid controlled. This would reduce engine warmup time.

To discuss our idea further we went and saw Gerry Hamilton as engines was his subject. Gerry quickly recognized a major flaw within this idea and very quickly discarded it. He told us that by removing the flow of coolant during engine warm up period we would create hotspots within the coolant around the cylinder block and cylinder heads. Thus resulting in engine damage. 

This was discouraging news as both me and Richard thought that this was a good idea. Roman then told us that we need to come up with an idea by the end of the second week. I must say I am feeling the pressure now. Two weeks have passed and still no project!   

Day One - Week One

Today was my first day of the new Technology Project Class. I must say I have been rather nervous about this class as previous students have given me mixed feelings about what to expect. I was pleased to know that our lecturer for this class was Roman. Roman explained to us what is expected of us. He insisted to not do anything complicated as the course was shorted to only one semester. (It was meant to be a two semester course).

This subject expects us to identify an issue within the automotive industry and try and come up with the solution for it. The solution must be different to what is already out there. Also the solution should be simple and up to the level six standard. Now I thought that we had to physically build something. But as Roman explained that the project can also be virtual. This was good news!

Richard is my buddy and he has been since the CAT days. So me and him decided to become partners and do the project together. Now I must say coming up with an issue and coming up with an solution to that particular issue is rather hard and thus far me and Richard are clue less as to what we are going to do??