The Application of an Engineering Design Methodology - Dry Sump Design - Case Study Example

Dry Sump Design Name: Course: Lecturer: Institution: Date: Table of Contents 1. Introduction 1 2. Problem statement 3. Objectives 4. Methodology 5. Design concepts 6. Conclusion 7. Recommendations 8. Bibliography 9. Appendices Dry Sump Design Introduction In the current engine systems, the gas turbine varies by the construction and plumbing procedures. The dry-sump system design needs to have lubrication and cooling system that prevents overheating of the engine during the high load of the engine. This may be done through pumping of the cooling oil to the system. However, when the engine stops there are chances that the engine might experience higher chance to be worn out due to the heating effect developed during racing. As the engine continues to consume a lot of fuel to run the extra weight of the racing car, there are chances that there would be leaks from the engine. Therefore, a better design that uses less oil lines is designed in this case report. The development of the engine involves reduction of the oil lines by application of basic but clever engineering by reducing the whole system to have oil flow from the oil tank via the engine to scavenge pump. This way the number of oil lines is reduced from the initial one, which had oil to flow from oil tank to pressure pump, then through the engine (Randy, 2011; 109-112). This is cleaned at a distant strain then back to the engine, then it flow back to the oil tank via the scavenge pump and oil cooler. The two designs (full old design and the reduced design) are shown in figures 2 and 3 respectively. For the reduced system the oil needs to flow through only three lines, which be reduced to even two lines. This way the cost of running the car also reduces. For proper functioning of this system Gilmer belts are required to drive the three external pumps which passes oil through only one scavenge pump. Furthermore, the external force pump is not necessary since the engine can develop its own power to pump the oil by changing the oil line to flow to the external line from the sump. The engine design should have a crank placed pump, which makes the 4AGE to run the pump up the side of the pump thus enabling easy oil pumping to the engine. Problem statement The need to develop a powerful engine system that can be used in sports and having a strong engine that will be able to tackle high speeds without overheating and yet deliver maximum power. For example, the CAMARO engine and Ford design uses a dry sump system, which helps the engine to have high power delivery to enable the vehicle to manage high speed without overheating. Objectives The main of designing the dry sump is to acquire skills on designing and implementation of one’s skills to deliver theoretical and practical experience. Also, through the design of the dry sump it helps to learn how manage his or time plan in designing a real technological design to achieve a goal. Methodology Most of the dry sump systems have oil flow from the external reservoir tank which is pumped by the pressure pump to the engine then it is passed through remote oil filter then back to the engine (Potak, 2011; 89-97). Oil from the engine then passes through the scavenge pump and the oil cooler back to the reservoir tank. The proposed designed in this case uses the following parts an oil reservoir, a separate external oil pump and a sump pan that is used to scavenge the oil from the system shown in figure 1 in the appendix. The design of the dry sump system is a shown below Design concepts Figure 1: A schematic drawing of oil flow in the system For the above system, the oil pan is located such that it is at the lowest side of the engine. This positioning helps the movement of oil from pan to the engine, then to other parts of the oil passages so as to enable the flow to the block. In the pan, the oil flows back after the lubrications and doing other works that involve the use of oil from the oil tank. After the oil flows to the tank it starts over , and the flow continues to allow oil to flow to the portions of the engine that requires lubrication. Since this process is a simplification process, the entire system has a number of processes that are taking place and this helps in the development of the engine dynamics. When the system is, complete the oil working at exceedingly high pressure from the pan and pump the oil system works remarkably to cover the deficit. However, if the system works hard to force the flow of the oil then, there is a chance of having high amount of oil flowing to other parts of the engine, and this is not economical. Sometimes the oil does not move back to the pan as expected; hence, it forms a pool or a valley lifter of oil. In this case, there might be chances of starvation in the engine parts during the pump pickup. Another reason may be attributable to the g-force caused when the car is about to take a round corner, which makes starves the pan from the pump pickup. Changing the dry sump design to the above design ensures that the amount of oil pumped to the rods and the crank of the engine. For the design in fig 3, the oil flows from the storage tank and is pumped by the scavenge pump to the external tank for cooling. The external oil pump then pumps the cooled oil to the lubrication area. On the fig 4, oil from the storage tank is passes to the filter then to the cooling tank then passed to the lubrication area in the engine. The process continues to the filter from the pump, then to the engine lubrication parts. Design considerations The system has to use single stage scavenge to ensure that the pump feeds the required oil to the engine for cooling as required by the system. In modifying the tank, the blanking pug is removed so that the oil line from the oil reservoir tank is connected to the system. For these connections to be successful, the dry sump system has to have a remote filter for the two lines, that is, to and from filter and oil big filter (Tony, 2008; 309). Another connection that the sump should have is to connect the blanking plug to enable one filter to do the work. Point to note is that the filters can stay alongside the block for increasing efficiency. My recommendation for this connection to replace the cooling tank is that, you connect an intercooler by fitting water-oil connection. Although there are non-oil advantages of using the dry sump system, it has one significant risk of placing the oil reservoir externally. Placing the oil reservoir externally has a drive belt which serves as a liability and this may be termed as a risk if there is a case of belt damage whereby the belt jumps off. Apparently, this fault can be solved by using mitigation measures such as encasing the belt in case it is damaged it does not jump off , but it is withheld in that casing thus reducing the risk chances. When the dry sump system is used in the non-oil related application the oil pan may be positioned at any distance that ranges from 2 to 5 inches. This way the engine mounting process in the chases is rather easier and has fewer complications than the installation of the engine in the chases, which has a wet sump design (Stolarski, 2000; 45-50). In addition, there is an option to improve the car handling through lowering of the engine and through this the air stream would be lower than the nose. This way the performance of the car is improved. Another advantage of using a dry sump system is that by placing the oil pump externally, the car speed may be controlled through pulley adjustment to have different sizes. Compared to the wet sump designs, the dry sump system has an option. Nevertheless, for the wet sump design no options for pulley adjustments, only fixed sizes. Description of the components 1. Filter element The principal intention of this component is to help in filtering the materials that are at high temperature and they may contain inorganic fibers as well as the organic fibers. This element is made of stainless steel mesh. When the pressures are high this mesh helps in preventing collapse due to mechanical weaknesses. 2. By pass indicator This component allows for ease in access to the filter. Through this component, it is rather easier to manage pressure difference in between the filter inlet and the filter outlet. It is designed to have a magnetic button that helps in controlling the filter pump. 3. Bypass sensor The inlet filter through the bypass sensor, it determines the differential pressure to allow the inflow without the out flow from the engine to the scavenge pumps. This sensor by the principle of the spring that helps the system to close and open to control the filter between high and low pressure to and from the engine. 4. Scavenge and lubrication pump Internal parts of the Gyrators of the scavenge pump are tightly screwed to the shaft to ensure that the shaft has individual locomotor rings that are eccentric. 5. Relieve valve for Cold oil Overpressure may occur due to cold starts in the engine. Therefore, using the relieve valve this effects may be avoided and controlled and ensure that the engine runs smoothly. It is ideal to have all valves of the engine functioning as required to prevent system failure which may occur due to over pressure that can be controlled through the relieve valves. 6. Oil cooler The cooler has a design of a tube. Its purpose is to cool the oil from the engine through the scavenge pumps and the gearbox. All these parts work in hand with each other to complete the functioning of the dry sump system as expected to attain the maximum results. Conclusion Keeping the oil reservoir away from the engine is the only solution to make the engine to run smoothly without overheating and thus contributing to the robustness of the system. For the purpose of supplying the oil to the system without starvation as well as using a separate pump it helps to remove and scavenge the oil flow to and from the engine for the pressurized oil from the engine. Dry sump system when properly designed they help in developing a high horse power for the racing engines thereby creating a high performance. In order to create high performance of the dry sump system, there have to be a multistage design of the pump, oil pan which is different from the engine connection, a tank, mounting brackets and various hoses. Although the cost of the design might be high, the system operation price effective and thus at the long run it saves maintenance costs. Using the dry sump system for the engine design leaves user to get total control over the oil system. The high performance of the dry sump system is attributable to the concept of impellers that help in the pressuring the oil through the engine. This system involves a number of stages involving different pumps planned to work the way but at different stages. This way each pump does its own job and thus improving the performance of the car. For the design to be effective, then two scavenge pumps and single pressure pumps must be there. Scavenge pumps maximize the cleaning by removal of oil off the system while the pressure pump supplies the engine with oil. This system is three stage pump, where by the scavenge pumps controls the oil movement to the reservoir tank without any loss or delay. The purpose of the pressure pump is to control the oil flow pressure to the engine through the filters. As one may consider a dry sump system replacement costly in the short term, it has a higher cost effectiveness in the long run (Andy, 2009; 207-210). Therefore, changing the engine design and improving the performance is actually an ideal way in which performance may be attained. This in turn may result to durable design, elevated power production, and increases engine performance. Recommendations As a matter of improvement, the engine should at least have two scavenge pumps and a single pressure pump to enable cleaning of the crankcase by removing the vacuum left in the crankcase. This way as one tries to design a better dry sump system it creates a positive improvement of the engine. In essence, using the system that has the two scavenge pumps helps in lowering the crankcase pressure, which results in the improvement of the ring seal. Therefore, using the design a low-tension ring may be developed thus ensuring low drag on the engine bores as well as lowering the level of friction of the engine. At least the dry sump system with such part can develop about 19 to 22 horsepower for the engines. Long racing wears out the engine. So it is necessary to have the replacement part ready for the job. This is an advantage of using the dry sump system in that the parts of the dry sump can be rebuilt. Therefore, it is necessary to have dry sump checkup of the parts from time to time. This way proper running of the engine is considered and the rate of risk that may arise from the worn out dry sump parts is taken care off. Bibliography Andy, F. (2009), Max-Performance Mopar Big-Blocks, England: CarTech Inc. Tony, P, (2008), How to Build Motorcycle-Engined Racing Cars, New Jersey: Veloce Publishing Ltd Potak, J. (2011), GM LS-Series Engines: The Complete Swap Manual, England: Motor Books International. Stolarski, T. A. (2000), Tribology in Machine Design, New York: Elsevier. Randy, L. (2011), Porsche: A History of Excellence, England: Motorbooks International Appendices Figure 2: Dry sump design Figure 3: General design of oil flow to the engine Figure 4: Dry sump flow Read More