1. Small Engine Emissions Reduction Project 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. Catalyst Made up of two parts  Housing  Substrate Honeycomb coated with the metallic catalyst Replaces existing muffler Can be EPA certified as separate unit

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. Propane Engines Available 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

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. 1 st Horizontal Shaft Propane Solution 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 Kohler CH14 LPG

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. Closed Loop System Engine Control UnitMetering Valve Carb Intake Manifold Engine Oxygen (O 2 ) Sensor Exhaust Catalyst Exhaust- H 2 O CO 2 N 2 Air Propane

26. Engine Performance Analysis

27. Propane Tank Selection “Fork Lift” style 20lb tank due to size constraints EngineAmount/Type of FuelEndurance Honda GX3907 gallons Gasoline6 hours Kohler CH1420lb propane tank4 hours

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

29. 2 nd 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