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redesign solenoid engine

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bazil arashi

on 20 April 2015

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Transcript of redesign solenoid engine

Final Year Project 2
The objective of the project are:
• To re-design Solenoid Powered Engine

• To re- design firing order for Solenoid Powered Engine

• To produce working prototype

Process DEvelopment
construct (mk2) 2 solenoid engine
4/1/ 2015

Electric Vehicle are becoming increasingly attractive alternative to the car with combustion engine, considering the effect on the environment as well as economic factors such as gradual increasing price of fluid fossil fuels and others. Due to the fact that these vehicles are widely known for their zero emission and powered by renewable energy sources.
In general, EV are driven and controlled by the integration of electrical, electronics and also mechanical components but the main component that actually moves these vehicles is the electric motor.
Electric motor on principles of the electromagnetic by converting electrical energy to kinetic energy.
This energy conversion is the main purpose of an electric motor and this actuator are highly popularized in most EV’s designs.
The idea of the project is to take another alternative design of EV prime mover to replace existing electric motor.
more reliable, less maintenance, fewer parts
In methodology, in order to Complete the prototype, there are several stage need to be completed:
gantt chart
process development
operating diagram
project cost
Redesign Solenoid Powered Engine in Automotive Industry
Process Development
construct (mk3) 4 solenoid engine 12 vdc
Process Development
construct (mk4) 12vdc and (mk5)16 vdc, 4 solenoid boxer type engine
24/2/2015, 24/3/2015

Process Development
idea creation
Process Development
Construct (Mk1) single solenoid engine
brainstorming on design development
identifying the materials, component, tools
Construct the prototype
testing the prototype and demo
Process Development
Idea Creation:
To build another alternative of Electrical powered engine which is more reliable,less maintenance, compact and less energy consumption
Process Development
brainstorming on design development
several model has been observed based on their specification and design:
This prototype that made by Nigel Taylor, the engine runs using a simple 9V battery and just a simple flick of the flywheel.

The connecting rod was made using two brass bushes and some thin copper tube flattened and then soldered to the brass bushes.

Using micro switch as a trigger the electromagnetism

1) Single Solenoid Powered Engine by Nigel Taylor
The engine is a 90-degree V8 that uses a crossplane crankshaft and is made from scrap metal, and some other odds and ends.
Rather than reinventing the wheel (or engine in this case), he built the engine to work on a big-block Chevrolet firing pattern – 18436572 – and it uses a camshaft to actuate the solenoids every two revolutions of the crankshaft, just like a four-stroke combustion engine.
Engine speed is regulated by a simple dial mounted on the side of the platform.
Solenoids are switched by the relays, which are triggered by the camshaft. The camshaft is geared to runs at half engine speed through the timing chain. Revs tops out at 460 on a 3-amp power supply.
2) Solenoid Powered model V8 four-stroke engine by David Robert
2) SPE Prototype Model 4H17U-1 by Syed Zainal Abidin Syed Kamarul Bahrin et Al
The SPE characteristics are based on prototype model 4H17U-1 as shown in the above figure.
This prototype model is powered by 48V power supply, using four solenoids rated at 24V each and controlled by PIC series micro controller.
Technical details: 60 degree V12 - runs on 24v dc fixed - "cylinder bore" 8mm, Stroke 10mm, theoretical total displacement is just 6cc, sealed roller bearings 684zz (4x9x4mm) are used for the main and big end bearings, the flywheel bearings are larger (4x13x5mm) to handle the weight of the flywheel (900g),
the crankshaft is made up of one hundred and forty individual parts, and is counterweighted to balance the rotational mass (the reciprocating mass cancels itself out in the v12 design), the flywheel is an old drill chuck, the tachometer pickup is on the rear of the timing / distributor shaft, solenoid model used: SOLEN 121E16530, these solenoids have built in flyback diodes,
the switching transistors are 2N3055. The engine is running as a 2 stroke here but can also run as a 4 stroke at the flick of a switch.
4) v12 solenoid motor by david robert
Materials for the prototype
Process Development
Process Development
construct (mk6) 4 solenoid v type engine
Process developement
construct (mk7) 4 solenoid v type engine
Process Developement
Testing on Prototype and Demo
output that produce by the prototype:

Power: 13.6 watt

Speed: 3000 rpm average

Voltage produce from rotation of motor: 7.6 volts average

Torque: 0.00072 Nm
Operation diagram
Gantt chart
Planning Gantt Chart
Actual Gantt Chart
Project Costing
rm 505.80
output calculation
Power in hp:?
Watts: 13.6 watts
1 hp= 745.69 watts
hp= 13.6/745.69
= 0.0182 hp
T=power(Watts) /(2pi x rpm)
= 13.6 /(2(3.142) x 3000)
=0.000721502 Nm
Power to Weight ratio= (Power/Weight)
Power(hp)= 0.0182
Weight (Crankshaft) = 300g = 0.3kg x 2.204 = 0.6612lb
= 0.0182 hp/ 0.6612lb
=0.0275 hp/lb
1) 16VDC Solenoid Open frame (STC-08a-103s)
2) Bearing ABEC 5
3) 8 shape steel bracket
4) custom rod
5) soleoid holder wood block
6) L bracket
7) Limit Switch
1) Rc helicopter rotor gear
2) hardisc small bearing
3) hardisc platter
4)motorcycle handle bar protector
6) 24v rechargeable battery
7) motorcycle chain shim
8) custom crankshaft
Assuming the power consuming for actual engine.
Power to weight ratio = 0.0275 Hp/lb
Actual engine Weight (crankshaft +Flywheel) 14kg
=14kg x 2.204=30.856lb
Power (hp)= ?
Power (Hp)/30.856lb =0.0275 Hp/lb
Hp= 30.856 x 0.0275
= 0.84854 hp
1 hp= 0.7456kW
0.84854 hp = 0.6303kW
=630.3 W

*by theorically, used 10 of Solenoid KD09D by Solen Electic.Co which is suitable because each of them can produce 72 Watts
Prepared by: Putera Bazil bin Bazid
Supervisor : Engr. Noor Azammi Abd Murat
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