Small Engine Emissions Reduction Project Number 06109

1. Small Engine Emissions ReductionProject Number 06109 Sponsor: Stone Construction Equipment, Inc. Team Members: Celeste Luce (Team Leader – Mechanical Engineer) Benjamin Heiser (Mechanical Engineer) Mark Siemer (Mechanical Engineer) Brent Smith (Mechanical Engineer) Coordinator: Dr. Alan Nye Mentor: Dr. Ali Ogut

2. Project Overview • Stone Construction Equipment • The Mud Buggy • Emissions

3. Mission Statement • Develop a new design or modification that provides a cost effective solution to reducing emissions on the Mud Buggy. The desire is to be able to use the equipment manufactured by Stone Construction within unfinished buildings, without risk to individuals using the equipment. This design must comply with EPA regulations, and if used in an confined environment, meet OSHA standards.

4. Design Process • Needs and Objectives • Brainstorm and Develop Concepts • Feasibility Assessment • Best Concept • Engineering Analysis and Complete Design

5. Needs and Design Specifications • Develop an engineering model which: • Lowers emissions • Maintains EPA certification • Is low cost • Is aesthetically pleasing and marketable • Is able to fit through an unfinished door • Fits inside current plastic housing • Is consistent with current power and safety features • Does not void original engine manufacturers warranty

6. Performance Specifications • Engine must have 13 HP • Comparable fuel usage • Must be able to push the hydraulic pump over relief without stalling (2900 psi) • Must be able to keep a consistent flow rate of fluid out of the hydraulic pump

7. Emissions Regulations • Environmental Protection Agency • All engines sold must be EPA certified • California Air Resources Board • All engines sold in California must be CARB certified • Occupational Safety and Health Administration

8. Concept Development • Electric Power • Catalyst • Alternative Fuels • Propane • Biodiesel • Forge Technology Partnerships

9. Electric Power • Near zero emissions • Requires use of batteries and/or generators • Multiple motor control options • High energy efficiency • No market at this time • Manufacturing

10. Made up of two parts Housing Substrate Honeycomb coated with the metallic catalyst Replaces existing muffler Can be EPA certified as separate unit Catalyst

11. Catalyst – DCL International Inc. Exhaust gases enter the catalyst and react with the substrate resulting in the creation of water and carbon dioxide. This results in a decrease of carbon monoxide, hydrocarbons, and particulates

12. Honda GXV390 LPG 13 Horsepower Vertical shaft orientation Kohler CH14 LPG 14 Horsepower Horizontal shaft orientation Briggs and Stratton 480cc V-Twin New Development 16 Horsepower Horizontal shaft orientation Propane Engines Available

14. Propane Mounting Options • Honda GXV390 • Vertical position • Gears • Horizontal mounting • 90 degree gear box • Belt/Chain • Kohler CH14 • Maintains current configuration Current configuration of the Mud Buggy

15. Vertical Mounting • Does not fit inside cowl • Custom adapter

16. Honda Propane Vertical Configuration Engineering Model Cost: • Honda Propane Vertical Shaft Engine: $521 • Regulator Kit: list price $300 • Propane Tank: $151 • Custom Adapter: $20 • Engine/Pump Stand: $30 • Additional parts and manufacturing needed: $200 • CO testing equipment and other safety requirements: $800 • Rough Estimated Total: Approximately $2001

17. Running the Hydraulic Pump with a Belt or Chain • Energy Lost • Overhung Load Adapter • Size Constraints

18. Honda Propane Vertical Configuration Engineering Model Cost: • Honda Propane Vertical Shaft Engine: $521 • Regulator Kit: list price $300 • Propane Tank: $151 • Sprockets or Pulleys (custom + common): $50 • Overhung Load Adapter for Hydraulic Pump: $700 • Belt or Chain: $12 • Engine/Pump Stand: $30 • Additional parts and manufacturing needed: $200 • CO testing equipment and other safety requirements: $800 • Rough Estimated Total: Approximately $2651

19. 1st Horizontal Shaft Propane Solution Kohler CH14 LPG • Advantages • Engine includes two-stage regulator • No frame modifications • Use existing adapter • 12 Volt electric system • Significantly lower emissions • No additional calibration necessary • Disadvantages • Less horsepower and torque • Cost of engine

20. Kohler CH14 • Directly bolts to existing adapter • Exhaust opposite side

21. Engineering Model Design

22. Bill of Materials

23. Cost Comparison • Cost of new components: $2207.55 • Cost of components no longer needed:- $ 527.39 • Cost added to the unit: $1680.16

24. Emissions Analysis

25. Metering Valve Engine Control Unit Propane Oxygen (O2) Sensor Intake Manifold Exhaust Catalyst Carb Engine Air Exhaust-H2O CO2 N2 Closed Loop System

26. Engine Performance Analysis

27. Propane Tank Selection • “Fork Lift” style • 20lb tank due to size constraints

28. Testing • Stall Test • Dump Speed Test • Travel Speed Test • Flow Rate Test • Noise Test

29. 2nd Horizontal Shaft Propane Solution • $678.46 • Requires regulator & fuel lock-off • Requires CO tester and additional calibration • To be investigated further Briggs & Stratton V-Twin

30. Plan for Senior Design II

31. Questions?

33. House Of Quality Analysis