Hydrogen Car Conversion

1. Hydrogen Car Conversion Justin McBath Paul Miller Nick Rader Edward Yates Jonathan Blanco Joe Branam

2. Outline Introduction Recap of Midterm Tank Mount Hydrogen Plumbing Fuel Delivery Apparatus The Spider Manifold Electronic Fuel and Ignition Control Injector Analysis Engine Management System

3. Outline cont. Pressure and Temperature Display System Business Case Budget Analysis Summary Conclusion

4. Introduction This is the second semester of the H2 Saturn Conversion Project. We applied the engineering analysis performed in 385 to develop the hydrogen conversion system for the Saturn Vue.

5. Discovered Problems Using Hydrogen Power Loss Pre-Ignition Leaks Tank Pressure and Size 5000psia Approx. 4.26kg Method of injection Electronic Port Injection Recap of Midterm

6. Recap cont. Determined Testing Cycle Five Laps City Highway

7. Tank Mount Tank mount attached in rear section of vehicle Mounting base bracket

8. Tank Mount (cont.) Tank Mounting Bracket Attached to Frame of Vehicle Designed to Secure Tank in Case of Collision

9. Tank Mount (cont.) Supplied tank mounting brackets will be attached to the constructed frame mount.

10. Plumbing

11. Hydrogen Plumbing High pressure and corrosive environment Fully annealed, seamless stainless steel (SS), 3/8� Rated minimum pressure of 5,000 psia The tubing is seamless to ensure a leak-free connection

12. Hydrogen Fittings Swagelok compression fittings incorporate twin ferrule seals to prevent leaks

13. Hydrogen Leak Sensors

14. Fill Receptacle 5000 psia hydrogen fill receptacle Built in check valve

15. Internal Tank Solenoid Allows hydrogen at 5000 psia to enter the tank Allows hydrogen at 5000 psia to leave the tank Built in pressure release valve High pressure port for hydrogen sensor

16. Tank 5,000 psia H2 storage tank DOT approved Carbon Fiber Tank

17. Pressure Regulator Reduces pressure from 5000 psi Reduced pressure between 75-0 psi Fittings for a high and low pressure gages

18. Plumbing Schematic

19. Plumbing Schematic

20. Plumbing Schematic

21. Fuel Delivery Apparatus Intake Manifold Spacer

22. Fuel Delivery Apparatus Stock intake manifold spacer

23. Fuel Delivery Apparatus (cont.) Spider Manifold Drawing

24. Fuel Delivery Apparatus cont. Completed Spider Manifold

25. Dual Engine Management System

26. Engine Management System AEM ECU Sensor Inputs Pencil Coils Peak and Hold Injector Driver Injection System

27. AEM ECU

28. Sensors Intake Air Temperature (IAT) Engine Coolant Temperature (ECT) Throttle Position Sensor (TPS) Cam Position Sensor (CMP) Manifold Absolute Pressure (MAP) Crank Shaft Position Sensor (CKP)

29. Installed Sensors IAT ECT

30. Installed Sensors (Cont.) TPS CMP

31. Installed Sensors (Cont.) CKP MAP

32. Peak and Hold Injector Driver

33. Fuel Injectors

34. Fuel Mixture

35. Injection System Shows the flow rates with respect of injector hold times Required flow rate for our application is 2.054 (gal/s) @ 55 mph

36. Partial Range Display System Pressure transmitter 0 to 5000 psia range Sends a current signal Thermocouple type K(-50� C to 200� C) sends voltage signal Pressure and Temperature Display System

37. Thermocouples and Pressure Transmitters

38. Display Screens

40. Business Case Top Level Description Team Members and Org Chart Team Capabilities Analysis Competitive Analysis Risk Analysis Out-of-Bounds Criteria

41. Top Level Description Enable ICE to function using gasoline or H2 gas as its fuel source H2 conversion of 2005 V6 Saturn Vue New part installation and customization Existing component customization Current and Prospective Customer Base Engineering advisement mentors/professors General consumer use

42. Team Members and Org Chart

43. Team Capabilities Analysis Team Commitment Long lead items have been received excluding the tank 26 out of 29 milestones have been achieved Project Success Potential to be the first domestic H2 powered vehicle in Chattanooga Commitment to use as many OEM parts as possible Sound plan to integrate two separate ECU systems

44. Competitive Analysis Assets Intellectual Property Cash Real Estate Constraints External Parts acquisition Self-Imposed Time and team management

45. Competitive Analysis (cont.) Customers UTC Suppliers Over 10 suppliers

46. Competitive Analysis (cont.) Partners H2 Fueling Station Team Competition Battery Technology Fuel Cell Technology New Cheap Fossil Fuel Sources

47. Competitive Analysis Intellectual Property Currently, the Team does not own any Intellectual Property Patent Search was performed Generate ideas Mitigate IP infringement Future acquisition of IP Obtain Patents Trade Secrets Possible revenue source

48. Risk Analysis

49. Risk Analysis

50. Risk Analysis Focus of Failure Mode Effects Analysis Hydrogen Plumbing Electrical Components Engine Management Tank Mount

51. Risk Analysis Results of Failure Mode Effects Analysis

52. Out-of-Bounds Criteria

53. Original Budget Analysis Total plumbing cost $9,592.67 Total safety systems cost $2,435.00 Total electronics cost $328.50 Total fuel delivery system cost $1,577.87 Budget Total Before Range Display $14,000.00 Original Contingency $65.96

54. Final Budget Analysis Total plumbing cost $9,567.67 Total safety systems cost $2810.00 Total electronics cost $3151.70 Total fuel delivery system cost $1049.48 Total pressure/ temperature display cost $1475.00 Final Budget Total $18,500

55. Final Budget and Cost Cost to Date : $18,053.85 Final Budget Total: $18,500.00 Contingency: $446.15

56. Budget Comparison Plumbing under $25.00 Safety Systems over $375.00 Electronics over $2823.20 Fuel Delivery System under $528.39 Pressure/ Temperature Display over $1475.00 Total difference $4119.81 over

57. Summary Recap of Midterm Tank Mount Hydrogen Plumbing Fuel Delivery Apparatus Electronic Fuel and Ignition Control Pressure and Temperature Display Business Case Budget Analysis

58. Conclusions Using several different aspects of engineering; thermodynamics, fluid mechanics, and even electrical practices, a sound plan was developed to enable a gasoline fueled vehicle to operate on hydrogen or gasoline. Conversion is expected to be completed by the end of next week

59. Questions??