A Proposal to Design and Build an Intercooler Assembly with R-134a Integration
Submitted to: Professor Richard L. Roberts
Eric Brouillard
Brian Burns
Naeem Khan
John Zalaket
2/7/2011
WENTWORTH INSTITUTE OF TECHNOLOGY
MECH578
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Table of Contents
Introduction ........................................................................................................................................................................ 2
Problem ............................................................................................................................................................................... 2
Background Research .......................................................................................................................................................... 2
The Need ............................................................................................................................................................................. 3
Objectives............................................................................................................................................................................ 3
Functional Requirements .................................................................................................................................................... 3
Work Plan ............................................................................................................................................................................ 4
Qualifications ...................................................................................................................................................................... 4
Budget ................................................................................................................................................................................. 4
Future .................................................................................................................................................................................. 4
Bibliography ........................................................................................................................................................................ 5
Appendix A .......................................................................................................................................................................... 6
Appendix B .......................................................................................................................................................................... 8
1. Eric G. Brouillard ........................................................................................................................................................ 9
2. John P. Zalaket ......................................................................................................................................................... 10
3. Brian D. Burns .......................................................................................................................................................... 11
4. Naeem Khan ............................................................................................................................................................. 12
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Introduction
The purpose of an intercooler in a forced induction vehicle is to lower the air temperature flowing into the motor. An intercooler is a simple heat exchanger that works via airs need for finding a thermal equilibrium. This can be summed up by the Second Law of Thermodynamics. Simply put, heat flows from areas of high temperature to low temperature. In the case of a turbocharged vehicle, intake air is forced in through a mechanism known as a turbocharger. The turbocharger fan blades are propelled via exhaust gasses exiting the combustion chamber of the engine. These gasses heat the turbo, thusly detrimentally heat the intake air. This air needs to be cooled before entering the motor for two reasons; efficiency and mechanical safety. If the air is cooler, this will both increase horsepower as well as gas mileage, thusly increasing your fuel efficiency. Regarding mechanical safety, if the intake air temperature is too high, internal detonation can occur, thusly harming the vehicle’s internals. There are a few key drawbacks to the current intercooler design used in most turbocharged vehicles on the road today. First off, they are purely an air-to-air design, meaning that air flows through fins that are connected to channels. These channels are what contain the air flowing through them that you are looking to cool. This design works perfectly fine if you are moving, but if you are stuck in traffic, this design possesses a large flaw. Virtually no cooling will take place. Secondly, this style intercooler cannot get the intake air anywhere near as cool or cooler as the environmental air. This means that if it is a 110°F day out, the intake air cannot get below 110°F. From a performance and efficiency standpoint, anything above a 100 degree air charge is awful. By taking the existing air-to-air intercooler design, and routing the existing air conditioner refrigerant (R-134a) through it, we hope to achieve a much cooler and thusly denser air charge.
Problem Turbo-charged engines in vehicles function with an intercooler of limiting cooling abilities. As a result, optimum power output and efficiency may not reach its potential.
Background Research
Heat exchangers can come in many sizes, types, and styles. The basic premise of these mechanisms is to allow heat to flow from one fluid to another, without coming into contact with each other. These fluids can be either liquids or gasses. See below for diagram:
Both the intercooler for a turbocharged vehicles forced induction system, and the cars air conditioning system
function due to heat exchangers. The intercooler is mounted in the front of the vehicle (either in the grill or in the front
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of the fender) in order to allow air from the environment to flow through the fins. This lowers the air temperature of the internal air being forced through the intercooler on its route to the intake.
Simply put, air conditioners are made possible due to two principles. One being the same as the intercooler, but the other is due to what happens when fluid’s temperature when compressed. When the R-134a is compressed, the gas gets hot my absorbing heat around it. This fluid is then routed through a series of heat exchangers in order to dissipate that heat. Finally, when the pressure is reduced, this liquid becomes very cold. This cold liquid is now routed through a separate heat exchanger, where the cabin air is flown through, and thusly lowering temperature. See Below for diagram:
The Need In today’s advanced forced induction vehicles, efficiency is held paramount. Due to rising gas prices, fears of global warming due to pollution, and the thrill of increased horsepower, it is necessary to squeeze every bit of power out of a 4 cylinder engine, while retaining or even increasing fuel mileage. The purpose of a turbocharged vehicle’s intercooler is to lower the air temperature flowing into the motor. Cooler intake air temperatures facilitate better combustion due to the air being slightly denser. In theory, the cooler the air, the more efficient the turbo setup is being. Studies have shown that for every 10 degrees cooler air intake temperature, there is a 1% horsepower increase. Although this may appear negligible, in a 300 horsepower car, this equates to 3 horsepower increase with no increased fuel usage. If this was put into place across the world, thousands of dollars would be saved.
Objectives The purpose of this project is to create an assembly which is identical to the setup of an intercooler in a turbo-charged engine while integrating R-134a to decrease intercooler air temperature.
Functional Requirements
Construct a physical assembly for demonstration
Test assembly with real world conditions
Extract necessary data to satisfy objectives
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Work Plan The approach to a successful project will be determined by the ability to proficiently and professionally follow a systematic process. Referencing a schedule, tasks and due dates must be strictly adhered to. The first step is to brainstorm and compile potential solutions and alternatives. Once this is done, the engineering design process is to be implemented. This includes pre-planning, determining objectives and needs, actual designs, implementation, and all necessary concluding steps. See Appendix A for Gantt chart.
Qualifications Over the course of the last several years, all group members have had sufficient background in many disciplines which will attribute to the success of this project. A key feature to this project will be the actual construction and conceptual design of the assembly, where all members have had ample amounts of experience in. See Appendix B for Resumes.
Budget The majority of costs will be attributed to the gathering of equipment for the assembly construction. Parts needed are as follows:
Intercooler $50
Copper Tubing (50 feet) $60
Brake fittings $10
Miscellaneous supplies (screws, brackets, etc.) $50
$170
Future The ultimate goal for this project is to ideally have it implemented into a vehicle. For the purpose of the project for this semester we will have a conceptual design modeled with a demonstration assembly created. The demonstration assembly will be the base for a prototype which in the future can be used in a vehicle for real-time analysis. This could be a project that one of us may focus on later as an advancement towards a future career, or it can be used as a base for a future senior design project.
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Bibliography
A l b e r s , J o h n . " H o w D o e s a T u r b o C h a r g e r W o r k . " 1 . W e b . 5 F e b 2 0 1 1 . < h t t p : / / w w w . e h o w . c o m / h o w - d o e s _ 5 5 0 5 4 0 7 _ t u r b o - c h a r g e r - w o r k . h t m l > .
B e d e , C h r i s . " A u t o m o t i v e A i r C o n d i t i o n i n g S y s t e m s . " ( 2 0 0 5 ) : 1 . W e b . 5 F e b 2 0 1 1 . < h t t p : / / w w w . f a m i l y c a r . c o m / a c 1 . h t m > .
W r i g h t , M a t t h e w . " A u t o m o t i v e a i r c o n d i t i o n i n g d e s c r i p t i o n . " A i r C o n d i t i o n i n g : H o w
A / C W o r k s 1 . W e b . 5 F e b 2 0 1 1 .
< h t t p : / / a u t o r e p a i r . a b o u t . c o m / o d / g l o s s a r y / a / h o w i t w o r k s _ a c . h t m > .
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Appendix A
Task Name Duration Start Finish % Complete
Bring in Intercooler 5 days Tue 2/1/11 Mon 2/7/11 100%
Final Proposal 5 days Tue 2/1/11 Mon 2/7/11 100%
Website Design 64 days Tue 2/1/11 Fri 4/22/11 0%
Establish preliminary sketches
5 days Tue 2/1/11 Mon 2/7/11 0%
Mid Semester Presentation and Report
20 days Tue 2/1/11 Thu 2/24/11 0%
Weekly Friday Report 1 day Fri 2/4/11 Sat 2/5/11 0%
Final Design for Testing 5 days Mon 2/7/11 Fri 2/11/11 0%
Informal Class Presentation 1 day Mon 2/7/11 Mon 2/7/11 0%
Fully Functional Demo 25 days Mon 2/7/11 Mon 3/7/11 0%
Consult with Prof Duva 1 day Wed 2/9/11 Wed 2/9/11 0%
Weekly Friday Report 2 days Fri 2/11/11 Sat 2/12/11 0%
Compile all equipment for experiment
5 days Mon 2/14/11 Fri 2/18/11 0%
Weekly Friday Report 2 days Fri 2/18/11 Sat 2/19/11 0%
Weekly Friday Report 2 days Fri 2/25/11 Sat 2/26/11 0%
Weekly Friday Report 2 days Fri 3/4/11 Sat 3/5/11 0%
Design and Analyze Experiment on SolidWorks
12 days Mon 3/7/11 Mon 3/21/11 0%
Weekly Friday Report 2 days Fri 3/11/11 Sat 3/12/11 0%
Weekly Friday Report 1 day Fri 3/18/11 Sat 3/19/11 0%
Weekly Friday Report 1 day Fri 3/25/11 Sat 3/26/11 0%
Formal Report and Notebooks
21 days Fri 4/1/11 Fri 4/29/11 0%
Weekly Friday Report 1 day Fri 4/1/11 Sat 4/2/11 0%
Weekly Friday Report 1 day Fri 4/8/11 Sat 4/9/11 0%
Final Formal Class Presentation
6 days Mon 4/11/11 Mon 4/18/11 0%
Technical Poster 11 days Mon 4/11/11 Mon 4/25/11 0%
Weekly Friday Report 1 day Fri 4/15/11 Sat 4/16/11 0%
Weekly Friday Report 1 day Fri 4/22/11 Sat 4/23/11 0%
CD/DVD of all work 5 days Mon 4/25/11 Fri 4/29/11 0%
Course Evaluation 1 day Fri 4/29/11 Fri 4/29/11 0%
Student Self Evaluation 1 day Fri 4/29/11 Fri 4/29/11 0%
Weekly Friday Report 1 day Fri 4/29/11 Sat 4/30/11 0%
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Appendix B
Individual Resumes:
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Eric G. Brouillard 97 Roosevelt Avenue Extension
Preston, CT 06365 (860) 705 - 9911 [email protected]
EDUCATION:
Wentworth Institute of Technology Boston, MA Bachelor of Science, Mechanical Engineering Technology August 2011
GPA 3.425/4.000 Dean’s List: Fall 2008, Spring 2009 Relevant Coursework
Machine Design II, Fluid Mechanics, Material Science, Heat Transfer, Dynamics, Electricity and Electronics, Thermodynamics, Strength of Materials, CAD Applications II, Kinematics, Physics II, Differential Equations, Statics, Manufacturing Processes, Mechanical Graphics, Mechanical Design II, Instrumentation and Measurement, Mechanical Design Project
PROFESSIONAL EXPERIENCE:
ITW Ark-Les Stoughton, MA Mechanical Engineering Fall Internship September 2010 – January 2011
Designed and oversaw the manufacturing of test fixtures.
Tested and analyzed various automotive sensors and gauges.
Assisted in the design, testing, and assembly of Chrysler door handle sensors. BMW Manufacturing Spartanburg, SC Mechanical Engineering Spring Internship January 2010 - May 2010
Designed and fabricated Creform carts to better improve efficiency on the line.
Analyzed and modified process stations to comply with ergonomic and safety issues.
Completed VPS, or Value Added Production System lean manufacturing training. NAVSEA Supervisor of Shipbuilding (Supship), United States Navy Groton, CT Mechanical Engineering Summer Internship May 2009 - August 2009
Attended and obtained Yellowbelt level training in Lean Six Sigma.
Reviewed Engineering Reports and drawings for compliance with Military Specifications.
Approved for Secret Clearance. NAVSEA Supervisor of Shipbuilding (Supship), United States Navy Groton, CT Mechanical Engineering Summer Internship May 2008 - August 2008
Developed a database program for the engineering department to track daily tasks.
Created weekly and monthly performance reports for department head meetings. NAVSEA Supervisor of Shipbuilding (Supship), United States Navy Groton, CT Mechanical Engineering Summer Internship June 2007 - August 2007
Maintained files for incoming and outgoing projects.
Introduced to submarine design including new construction, repair, and modification.
Rotated through various engineering departments to understand the design process.
Learned the fabrication and manufacturing process through facilities tours.
TECHNICAL COMPETENCIES: Software: AutoCAD, SolidWorks, Catia, Pro E, Benchman, Working Model, Microsoft Office (Word, Excel, PowerPoint,
Project, FrontPage, Access, Publisher, Outlook), Visual Basics, Adobe (Photoshop, InDesign) Tools: Strength Analysis, Strain Gauges, Wind Tunnel Analysis, Flow Devices, CNC, Mill & Lathe,
Die Casting, Welding, Drill Press, Bridgeport, Manometers, Tinius Olsen Tensile Tester MEMBERSHIPS AT WENTWORTH:
Student Member: Mechanical Contractors Association (MCA) January 2009 - Present Student Captain: Intramural Floor Hockey, Ice Hockey, & Soccer Team September 2007 - Present
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John P. Zalaket 30 Hampstead Street Methuen, MA 01844
(978) 375 - 4463 [email protected]
Education Wentworth Institute of Technology, Boston, MA Aug 2011, exp Bachelor of Science in Mechanical Engineering Technology GPA: 3.124/4.0
Coursework Electricity & Electronics Fluid Mechanics Mechanical Drawings Manufacturing Processes Kinematics Thermodynamics Strength of Materials Mechanical Statics Technical Communication Differential Equations Chemistry CAD Applications Materials Science Mechanical Dynamics Machine Design Heat Transfer Special Topic/Project Measurement & Instrumentation
Technical Skills SolidWorks 2010 Windows XP Professional Microsoft Office 2007 AutoCAD 2010 Machining Microsoft Visual Studio 2008 Welding Metal Casting SolidWorks Simulation Minitab LabVIEW Engineering Equation Solver
Engineering Experience Vicor, VI-Chip, Andover, MA August 2010 – January 2011 Manufacturing Engineering Co-op
Used SolidWorks to designed X-Out Fixture to stop the placing of components of bad circuits saving the company
Worked on a rework process for J-Leads on VI-Chip units significantly reducing the amount of scrap
Used Minitab to perform statistical analysis of data to assist in the qualification of processes improving quality
Performed temperature profiles on reflow ovens to find best profile for minimal micro-voiding
Assisted in the day to day operations to help ensure smooth product flow
Partners Health Care Systems, Massachusetts General Hospital, Boston, MA February 2010 - August 2010 Automations Engineering Co-op
Calculated CFM totals to reduce airflow rates for buildings to make them more energy efficient
Programmed EnergyCAP for Partners Health Care Facilities
The program is very in-depth with the campus utilities and is used to track utility usage, calculate cost, and trend data
Managed and maintained two SQL Servers for EnergyCAP (one database server and one web-based server)
Redesigned mechanical drawings to engineers’ specifications for facility upgrades
ITT Industries (Flow Control), Gloucester, MA June 2009 - August 2009 Manufacturing Engineering Co-op
Designed and built a test fixture to test 1200 bilge pumps a day
Designed and built a test fixture to test circuit boards prior to production
Supervising multiple production lines to ensure that the process is smooth and timely
Diagnosed and troubleshoot issues during production to ensure that the process is smoother and more efficient
Lead multiple time studies to improve production time and cost (Lean Manufacturing)
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8 Crest Drive
Brian D. Burns Westford, MA 01886 978-846-3172 [email protected] EDUCATION Wentworth Institute of Technology Boston, MA Bachelor of Science in Mechanical Engineering Technology, GPA: 2.9 / 4.0 August 2011
COURSEWORK Manufacturing Processes Kinematics Chemistry Strength of Materials Fluid Mechanics Physics II Statics and Vector Mechanics Calculus III Mechanical Graphics Thermodynamics Machine Design Technical Communications
TECHNICAL COMPETENCIES Strength / Materials Testing Welding In-Depth Automotive / Motorcycle Knowledge Manual Milling CNC Milling Woodworking / Fiberglass Construction Manual Lathe CNC Lathe Spin and Sand Casting SolidWorks AutoCAD Microsoft (Word, Excel, PowerPoint)
WORK EXPERIENCE Morpho Detection Inc. Wilmington, MA Engineering Project Manager Co-op January 2010 – May 2010
Traveled to one of our vendors in Canada, leading a team to save the company up to $240,000 a year, by eliminating inefficiencies in consumables manufacturing
Increased, validated, and reverse-engineered product parts life through R&D work and testing
Organized and led multi-functional meetings, integrating the input of reps from all key departments E&D Machining Inc. / Louis C. Morin Co. Billerica, MA Machinist May 2008 – Present
Developed expertise in operating specialized machines including freehand and CAD/CNC milling and turning equipment
Performed quality control on products for use by companies such as Perkins School for the Blind and Howe Press, some of which were detailed parts for a Braille typewriter, laser optic lenses, and cover plates for military Hummer components
Constructed an array of customized parts based on CAD drawings, and inspected them all based on the ISO-9002 certification standards
Provided maintenance and repaired machines such as Nakamura Lathes, Robodrill Xi Mills, Hardinge Lathes, and Bridgeport Milling Machines
Sparks Stony Brook Acres Westford, MA Delivery/Sales Manager October 2004 – Present
Served as foreman-manager for Christmas tree sales as well as full manager while owner was on leave/vacation
Operated and maintained work vehicles to deliver trees and mulch, including Kubota tractor and commercial grade dump bed truck
Resolved customer issues, trained new employees, performed inventory control, payroll, and daily bookkeeping
PERSONAL EXPERIENCE Custom Automotive May 2005 – Present
Fully customized a turbocharger system, suspension system, and audio system on a 1997 Honda Accord
Transformed a 1999 Ford Mustang into a custom, show-quality vehicle
Rebuilt a 2001 Ford Mustang Bullitt into a custom, show-quality vehicle through a full restoration, including top-end motor rebuild and an assortment of performance and aesthetic upgrades
Building/tinkering on side projects (2000 Dodge Ram 1500, 93 Harley Chopper, 05 Raptor 660 ATV, Two Honda CB Bobber Projects)
Early Personal Experience Oct. 1993 – Oct. 2002
Attained skills at Microform Models Inc. from the age of 5 to 14 (family-owned spin casting/vulcanized mold processing business)
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Personal
Projects
Education Wentworth Institute of Technology Boston, MA
Bachelor of Science, Mechanical Engineering Technology August, 2011
GPA: 3.57/4.0 Dean’s List: Fall 2007-Fall 2008; Fall 2010
Relevant Heat Transfer Kinematics Mechanical CAD Applications
Coursework Strength of Materials Statics Fluid Mechanics
Thermodynamics Material Science Manufacturing Processes
Differential Equations Machine Design Physics I & II
Technical Software: Microsoft Office (Word, Excel, PowerPoint, FrontPage, Project), SolidWorks 2010,
Skills AutoCAD 2007, Minitab, Working Model 2005, Visual Basic.
Engineering: Strength Testing, Strain Gauges, Hardness Tester, Wind Tunnel Analysis, Sheet Metal,
Oxy-Acetylene Welding.
Machining: Lathes, Milling, Drill Press.
Devices: Computer Numerical Control, Sand Casting, Flow meters, Infra-red thermometers,
Tinius Olsen Tensile Tester, manometer, PLC control systems, USB data loggers.
Work Draper Laboratory, MCM-D Division Cambridge, MA
Experience Mechanical Engineering Student Associate January 2010
Collaborate with engineers to implement a Manufacturing Execution System
in order to track wafer progress and production.
Perform various experiments to properly qualify processes to be used in production.
Utilize Minitab and JMP to conduct statistical analysis for the purpose of
process control.
Design fixtures for various equipment to ease loading and unloading of product in
processing.
Health Alliance Fitchburg, MA
Developmental Specialist Summer, 2008
Assisted disabled individuals with various skills to accomplish Summer, 2009
goals involving physical therapy, communication, fine motor, and daily
life skills.
Brought clients into the community to learn necessary life skills.
Cerebral Palsy of Massachusetts Fitchburg, MA
Personal Care Assistant September, 2006-March, 2008
Served an adult with physical disabilities to help live at home independently.
Assisted in the physical therapy needs of the individual along with preparing
meals, transporting to appointments and locations requested.
Affiliation Society of Manufacturing Engineers, Student Member September, 2007-September 2009
Mechanical Contractors Association of America, Student Member September 2008
Rebuild of Small Internal Combustion Engines
Disassemble, evaluate, and repair engines to a functioning state to be used in lawnmowers, chainsaws, small
tractors, etc.
Complete Mobile Audio Installations
Researched and analyzed product specifications to achieve optimum setup.
Custom fabrication of speaker mounts to fasten new components.
Custom installation of upgraded wiring and components.
Participated in local sound competitions which were judged in loudness and quality of sound based upon quality
of installation.
Naeem Khan 26 Hartford St. (978) 407-0280
Fitchburg, MA 01420 [email protected]
