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Sorry to step on the other post, but this is how to bui... - 7/21/2008 12:31:59 AM   
Termyn8or


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Joined: 11/12/2005
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Well I said it and I am going to do it. I am going to tell you how to design a car. This can all be done with existing technology, but they won’t do it for a lot of reasons. One of them is that by the time you get something like this designed, you build it to last.

Go back to 1973 and get a Cutlass. Full frame, can handle it. Remember what I said 400HP and 40MPG. My Grampa would claw his way out of the grave and kill me if I tried to use a bigger frame than that for this. They can dress it up, but for this you need a full frame, no question about it.

And the floorpan will have to be modified for the transmission. You start off with the old 350, but you hook it up to a computer, one, maybe even two injectors per cylinder. Even give it a bit more radical curves on the cam, the electronics can make it run good anyway instead of how a racecar idles. They are already doing that, with sophisticated ignition control and multiple injectors, they made four cylinders run like a V6, and V6s run like
V8s. But with the focus on performance I am sure you can get 400HP out of a 350.

Should be a piece of cake, and really, but do we even care if it is only 300 ?
The tranny is the trick, and might require a bigger hump. It will contain an electric motor and a flywheel. The batteries for the motor are completely seperate from the system battery, and would probably be in or under the trunk.

Here is how it works, you hop in and start the car. You got it all on tap right then and there, and you just go where you are going to go. You get on the freeway and they don’t want to let you on, depress the accelerator and they will have nothing to say about it.
But eventually you do get on and once up to speed you back off, don’t want a ticket do you ? When you reach cruising speed, the engine actually shuts off, and you run on the electric motor. Of course it has real brakes, but if you just tap them to slow down, a DC convertor kicks in to charge the batteries, but first it makes sure the flywheel is up to speed.

To avoid ridiculous weight the flywheel needs to have a large diameter. This is why there might have to be a modification to the floor pan. Also the entire transmission will be quite a bit larger. The other engineers can deal with that.

You hit the gas and immediately the flywheel is connected to the engine, supplying starting torque, and if it can be done, some of the power to accelerate as well. And newer cars start very quickly. So this thing moves. I mean moves. I have had cars with 400 HP but nothing ever this light, you will be moving in notime.

But again, no matter how fast you want to go eventually you hit cruising speed, and when you back off, the engine shuts down and you run on an electric motor. When you hit the gas, power comes from the flywheel which is also used to restart the engine. You are movin, stoovin and proven. And getting good mileage. The V8 only runs when it has to, the rest of the time you are on batteries, which are charged continuously. But anytime you hit the gas pedal, the engine immediately restarts. This is doable with current technology. I know it is.

The transmission is the whole works. The motor will be built into it because I can see that it is the only way to make such a design practical. Otherwise it has the outward appearance of a normal rear wheel drive car, but within the transmission is a motor/generator as well as a pretty hefty flywheel. Both are "charged" whenever you hit the brake pedal. The drive wheels would most likely be driven by the normal planetary set, but the flywheel and the motor are connected by something akin to a CVT, or even have their own planetary gearsets. This would be a large transmission and that is one of the reasons that I think it should be done on a rear wheel drive. At least at first. Later when we know more maybe it can be adapted to smaller vehicles, and when the happens, think about it. If I can get 40 MPG out of a V8, what do you think this system could do with a V6 ? Or for that matter a four banger ?

One of the problems is the weight of the car. Airplay can be handled by making it aerodynamic, but acceleration and deceleration take energy. With good aerodynamics it might only take ten horsepower to propel it at a hundred miles an hour, but that is unrealistic. Though it can be done, it won’t. Being more reasonable, let’s go for twelve to fifteen horsepower at seventy miles per hour. That can be done and has been done.
And folks, I don’t know how many are really into engineering, but once the conveyance is moving at the desired speed, it’s mass means very little. The only thing is, if it is really heavy the tires will need a lot of air in them. As long as the drag coefficient is low, that is the only other factor, and it is manageable. The only problem is starting and stopping., THAT is what eats up the energy.

The exact suspension technology I dunno, I would have to say I might go with the Audi or Wolksvagon approach. American technology was good, but there is better, and if I am asking you for thirty grand, I better have something to offer.

With computer control and everything, it should be able to offer almost seamless performance. When it goes to start the monster under the hood, it needs to be on a one way clutch, when you lay down on it, the flywheel is connected to the engine, which is connected to the drive through a one way clutch. That way it doesn’t thump or put your head through the windshield, even if you forgot to put gas in it. And that could happen, hopefully.

At this point though I see it needs a mode in which it can lope home or to a gas station, to the extent that the drive batteries hold out. I do not see a big problem with that.

So that’s my idea, for good or for bad. It is the only way I can see to give the performance some people want, with the efficiency we need. Very complicated yes, but go take apart a helicopter if you think it is too hard. We are the US, and I want to bring something back. I want to see people actually pass a gas station in a car that can drive circles around this Jap junk.

I want to see this country come back from these dark ages, I want to see foreigners ordering these cars. I want to do SOMETHING. And none of this is any kind of pie in the sky shit, we HAVE the technology to do this right now. If some other people with money will come with me maybe we can get this done, I will put my money where my mouth is, but that is only so much money, and it is not quite enough. After the prototypes an assembly line must be built, that is not cheap.

But know this, it is an idea, and even if someone steals it, so what, it should help the world a little bit. I know full well that I can’t do it by myself, there are a few things I would have to outsource for sure. But I still got the idea.

I mean something DA would drive and plunk down the money. There are plenty of people in this country who can afford to buy something like this, but who can afford to build it ?

That is a bigger problem than most people think. I am not Henry Ford. And while I do have a measure of respect for the Man, I wonder where the money came from. See I am a realist. Yes it was a lot cheaper back then, but people used to make three dollars a week, and they were doing good !

Everything is relative.

T
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RE: Sorry to step on the other post, but this is how to... - 7/21/2008 6:16:21 AM   
petdave


Posts: 2479
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Honestly, you kinda have it backwards.

One advantage that electric motors have over gas engines is that they effectively have no torque curve. As a result, they're more efficient than gas when accelerating from a stop.

In order to get a DC motor to reduce speed, you reduce the voltage. Doing this takes a voltage regulator, which turns the excess voltage into heat. Wasted energy. So if you've got an electric motor running to keep the car at cruise speed, and that cruise speed is not requiring the motor to turn at peak RPM, it's wasting energy. And, if you're cruising on electric, then you could end up with very little charge time compared to the time that the motors are used, depending on the duty cycle.

To run a V-8 on fewer cylinders, by comparison, you stop feeding it gas (modern implementations collapse the lifters as well, IIRC), making it more efficient to run below performance peak (with some caveats- peak torque, rotating mass weight, etc). If you're going for extended stretches without using the engine, then it will drop below optimal operating temperature, reducing efficiency and increasing emissions.

Weight is also more of a factor than you give it credit for. A massive flywheel will be a horsepower drain in and of itself, particularly under acceleration. Then the weight of a full-size sedan will put a very heavy load on the electrics every time you start or stop. The problem tends to compound itself- a heavy car requires a heavier electric motor (or motors) to get moving, which require more or larger batteries, which makes the car heavier...

It's a very complex problem...

(in reply to Termyn8or)
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RE: Sorry to step on the other post, but this is how to... - 7/21/2008 7:17:17 AM   
MisterBeast


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First off, 73 was the first year the cutlass really started to suck, 68-72 were the good years, I would know, I have a 71.

Actually if you want to build the ultimate car, I would start with a truck. A 72 Chevy C/30 to be more exact. I would yank the stock engine and transmission, Install a Cummins 12 Valve that was tuned up to make about 600 FT/lbs of torque at the flywheel. (this can be done for less than 6 grand including the price of the engine) Then your going to need a NV4500 5 speed overdriven transmission, and a NP203 and a NP205 Transfer case so you can make a 203/205 Doubler to get a full 4:1 gear reduction range. Then put a 6" lift on it, 35" tires, and set your axle ratios at 3.73 when you install the front axle.

Put this setup togeather, and you will have a 11,000 lb truck that can actually do a ton of work, and get 25+ MPG and still be able to hit a lower range for offroading than your standard daily driver.

THATS DIESEL POWER BITCHES!


< Message edited by MisterBeast -- 7/21/2008 7:18:21 AM >


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(in reply to petdave)
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RE: Sorry to step on the other post, but this is how to... - 7/21/2008 12:27:13 PM   
Termyn8or


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Joined: 11/12/2005
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pdave, switched mode regulators are very efficient. The active output device is not just driven with DC, which would be very inefficient, it is switched on and off fast. Since it is on or off all the time it can be near 100% efficient. Such a circuit if used to decrease the voltage can actually put out more current than it draws. It is also almost the same circuitry that would comprise the DC convertor that would provide charging current for the drive batteries. Really, just about the same components, just configured a bit differently.

That, I got under my hat. What the real problem is to configure this whole mess. Also, on a system like that which I described, I might go with an electric oil pump for the engine. Remember it has to start and might have to put out near full power right away. Forget you ever had rod bearings in there.

The electronics is not a problem. If I just wanted an electric car I could design the regulator/convertor system right now. The problem is system control. The shifts and changes needed in the clutch system are more than any human operator would want to deal with, if he even could. When what happens, that will require a custom computer, which would be beyond just about anything in current vehicles.

If I were born about twenty years earlier I could probably do it all with hydraulics. I read the book on the THM400 transmission, and I mean THE book. It explains what every little piston in the valve body does, in fact it explains every part in detail. The technology amazed me, and I will tell you if I am going to race you in a car that has a THM400 in it, I will put it in drive. It knows better when to shift than I ever could. All this is explained in THE book. And THE book is from the year 1970. There was only one electric wire on these things and it was connected from the gas pedal, a switch that activates when you punch it, to a solenoid on the valve body which opens a bleed for IIRC the line pressure circuit. It changes the shift points to where in the right car with the right engine, it might stay in first gear up to 70 MPH.

My concept might be a bit off. Anytime you undertake to design and build something new, you find problems and pitfalls along the way, and you find solutions. Nothing on paper is perfect. Nothing is perfect, but when you hop in the thing and it works, that is about as far as mankind gets. Then to make it reliable.

But if they could build the THM400 way back then, what we can do now should be even better, but I said CAN. My Mother has gotten into brand new cars and drove them and said "There is something wrong with the transmission". Nothing on the market today shifts quite like the old THMs. We had to tell her "No, that's just they way they shift". I know EXACTLY why, and of course it involves money, but that is not the subject de jure.

The hydraulic system in a THM can be aptly referred to as an analog computer. No shit, an actual hydraulic computer. If I were to attempt this project I would simply use a computer, an electronic one. It is so much easier to design. The THM had pistons within pistons within pistons in the valve body. There is say a port, and line pressure forces the whole assembly through the bore, but when it gets to a certain point, that port or another closes and the inner pistons change relative position, which forms the hydraulic equivalent of what is called a Schmitt trigger in electronics. This keeps it from shifting fifty times a minute. It selectively ignores an input below a certain threshold. Truly an amazing machine.

In older carberated engines, there was always some loss of fuel during starting, but this is not true so much of a modern multiport fuel injected engine.

The trick to making something like this work is to realize the forces you have to deal with, and that is mainly stopping and going. In anything less than a panic stop, the idea is to return the energy that was used to propel the vehicle in the first place. That is where the DC convertors and batteries come in. The flywheel is only used to start the engine, and like I said if big enough, to lend the engine a hand in accelerating.

Every time you touch the brake pedal the thing downshifts and the motor becomes a generator, and somewhere alontg the line you have to tap the flywheel to keep it going. Of course if you slam on the brakes, there are real brakes, but in normal conditions, every attempt is made to use the energy of the momentum of the moving vehicle to recover energy. In the thirty thousand dollar car you may have now, when you hit the brakes, all of the energy used to accelerate the vehicle is dissipated in heat. This is very wasteful.

This is why electric cars can be viable, it is alot simpler to turn the system around to charge the batteries when you want to slow down. Conversely, in what most of us drive now, that energy is totally wasted. There is no practical way to turn a combustion engine around and put gasoline back in the tank. That, incidentally is why you don't call an engine a motor. Because it is not.

Maybe we should just go back to steamers. They run off anything that will burn. "How'd ya get here ?", "Well I'm burning that old couch, you know the one the dog pissed on". Literally. Heat and water. Tree in the yard screwing up the foundation of your house ? That's free gas.

Gasoline used to be burned out in the field because it was a waste product until Ransom Eli Olds came along and figured out how to use it. Yes of course there was someone in Europe doing just about the same thing back then, just like television, it got invented more than once. But they used to burn gasoline out in the fields, and look at us now. Four bucks a gallon.

Anyway, back to the point, 400 HP and 40 MPG, I think it can be done. No electric motor would do that. And if it did I doubt it would be as reliable because the current needed for a hard acceleration would probably burn it up.

I guess the point really is, that this technology is available now. Whether it is hydraulic or electronic, it can be done. Why nobody does this is because of money.

Let me put it this way, do you think car companies and oil companies are not in cahootz ? There is no way. One builds a product that is dependent on the fuel and quite a few other products derived from petroleum, and conversely, these products demand is fueled almost entirely by the automobile. There is no way in hell that they do not work together.

That may have something to do with the fact that they are practically giving trucks and SUVs away. You can almost trade a Honda Civic for a twenty thousand dollar Bill Blass decked out four wheel drive. Not quite, but it is getting close. I have heard of people trading their trucks straight up for fuel efficient shitcans. Losing thousands of dollars but it is that or they can't afford gasoline.

And MisterB, what you are talking about is quite different than what I am talking about, but now that you mention it, a truck body would make an excellent home for what I am talking about. The tranny would be quite overgrown, but there should be enough room in most trucks' chassis'. That would work for some, contractors for example, who put 150 miles a day in. But for alot of people a coupe or sedan would be a better choice because they are not carrying two tons of tools, and a car holds more people.

That's why we need something like the old Cutlass chassis. Everything viable now in the way of rear wheel drive passenger cars are over complicated junk, luxury cars.

And that's a whole nother point. I don't need the car to remember how I set the seat, I can set the seat when I get in. All these bells and whistles are getting ridiculous, and I guess what I am saying is that US auto manufacturers are still fucking up. And that is why they are losing money and that is why they a scaling back. They are losing. Why ? These are supposedly educated people, oh wait, maybe that is why.

Maybe I should contact them and see if they want to take a bite of this idea. I doubt it tough, I have no letters after my name. Fukum then. Maybe I should approach Honda or Toyota.

I have thought this out alot more than I could express. I mean even the fundamental mechanical design, which will of course need to be modified a hundred times, but what doesn't ? When you do something a new way it is extremely rare that you get it right the first time. That's what R&D means. Really figuring it out and Doing what it takes to make it work. And you thought it meant Research and Development. Don't be so silly. It's a big pain in the ass.

I can take and make it plain and simple, all you need to do is build this special tranny, there is a motor/generator inside and a flywheel. Complex ? yes. But they already overcomplicate things to the point where they damnear can't be fixed when they break. They like doing that. Captive service. They would love it if absolutely nobody in the world could work on anything aside from dealer service. Wouldn't you ?

Hmm, that is a point that might make my idea alot more appealing to them. I will have to think about it. Maybe I should do a patent search eh ?

T

(in reply to MisterBeast)
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RE: Sorry to step on the other post, but this is how to... - 7/21/2008 3:23:06 PM   
Vendaval


Posts: 10297
Joined: 1/15/2005
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I think this concept would be a good show for Spike TV.

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So in this gray haze we'll be meating again, and on that
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(in reply to Termyn8or)
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