Dox

1.
Engine layout and design:

Table 1 - Detailed Engine Parameters and Characteristics
Parameter Specification
Engine type Miniature two-stroke engine
Configuration Single-cylinder
Displacement 8.12 x 10-7 m3
Bore and stroke length 10 mm
Cooling type Air-cooled
Fuel type Paraffin
Power output 45 W (0.06 hp)
Fuel efficiency 11.895 mL per hour
Weight 0.07 kg
Ignition Compression ignition
Lubrication pre-mixed fuel (Paraffin and castor oil)
2. Installation details:
2.1 Mounting: The crankcase is designed to incorporate four standard M3 x 0.5 mm socket
head screws, which are 16 mm long. When mounting the engine to the frame, ensure that the
four screws line up with the four corresponding holes in the mounting blocks, these screws
need to be fully tightened so the engine remains stationary whilst running.
Figure 1- Engine aligned with mounting blocks.

Refer to Figure 1 when installing the engine to the two mounting blocks, the end of the
crankshaft should be facing the gear input shaft before the screws are tightened. The 4 mm
bush then slides onto the input shaft, allowing the flexible coupling to slide onto the
crankshaft and the 4 mm gearbox shaft. The flexible coupling then needs to be tightened to
ensure that there is no linear movement between the newly connected components.
Figure 2 - Flexible coupling connected to the crankshaft and input shaft.
Refer to Figure 2 when attaching the crankshaft of the engine to the gearbox, ensuring that
the crankshaft and gear input shaft both rotate freely when rotated.
2.2 Dimensions: Length: 90.70 mm, width: 48.00 mm, height: 50.95 mm
2.3 Required space: Ensure at least 25 mm of clearance space around all sides of the engine
to allow for sufficient airflow to take place, maximising the air-cooling effect.
2.4 Connection points: The gear input shaft has a diameter of 4 mm, and the bush that sits
on it has an outside diameter of 6mm, as this makes the crankshaft and the input shaft share
the same diameter. This, in turn, makes it much easier to achieve proper alignment when
installing the coupling. This also makes it much more likely to transmit the power efficiently,
minimising the amount that is lost whilst running. The carburettor connects to the crankshaft
case by screwing into the fuel port, which restricts the flow rate with a decrease in hole
diameter just before it enters above the piston head.
3. Service supply details:

3.1 Fuel system and lubrication: The chosen fuel type for the engine is paraffin, which
would be mixed with castor oil to provide the required lubrication to reduce the friction
taking place inside the engine. This would be mixed in a 50:1 ratio of fuel to oil due to the
high performance of the engine. The fuel capacity of the engine is 6.79 mL, which is more
than enough fuel for the engine to run for at least 30 minutes as stated in the project brief,
from the design validation report, the engine was calculated to burn 5.95 mL in the given
time.
3.2 Cooling system: The crankcase incorporates both an intake port, with a width of 8.76
mm and a height of 5.93 mm, and an exhaust port, with a width of 7.05 mm and a height of
5.06 mm. These ports help bring fresh, cool air back into the combustion chamber, replacing
the hot, combusted gases to prevent overheating. The cylinder head is designed to have fins,
all to increase the amount of surface area, as this means that more heat is being dissipated
away from the engine.
3.3 Spare parts availability: The recommended supplier for any spare parts is McMaster-
Carr; refer to Table 2 for the identification code of each part when ordering.
Table 2 - Purchasable Parts with Identification Codes
Part Name Identification Code

M3 Socket Head Screws 91290A120
Crankshaft Bush 6658K726
Gear Input Shaft Bush 6658K127
Flexible Coupling 8011N215
4. Testing and quality assurance:
4.1 Pre-shipment testing: The exhaust emissions would be tested when the engine is running
at full power using a gas analyser; this would be used to see if the engine complies with the
number of pollutants set out in the UK Emission Standards. The engine would be tested
running at full power to see if it can handle the load applied without it either failing or
undergoing excessive strain.
4.2 Performance testing: The fuel consumption would be tested to see whether the engine
can sustain full power for the required 30 minutes and at varying speeds. The rotations per
minute would also be tested to see if the engine running at full power meets the minimum
requirement of 12,000 rpm, as stated in the brief. The temperature of the engine would also
be tested to determine the maximum temperature of the engine whilst running.
4.3 Durability testing: The engine will be tested for long-term continuous use to see the
degradation of each of the parts without failing. The outcome of this test can then be used to
determine when each part needs to be replaced and help inform the maintenance schedules
after a certain amount of run time what needs replacing or cleaning. This, in turn, will
increase the overall lifespan of the product if the proper maintenance takes place.
5. Relevant codes:
Table 3 - Relevant Standards and Corresponding Codes
Category Standard/code
Safety General Product Safety Regulations 2005 (GPSR), UKCA Marking,
ISO 12100.
Gas emissions UK Stage V Non-Road Mobile Machinery (NRMM), ISO 8178
Noise emissions BS 7445-1:2003
Materials BS EN 573-3, BS 970, BS EN 10083-1:2006, BS EN ISO 19069
Fuel BS EN 15940, BS 650:1967
Environmental ISO 14001, ISO 14040
Technical Product BS 8888:2017
Documentation
Table 1 shows the relevant standards and the applicable codes for the different stages of the
engine's lifespan; this ensures that the engine meets the regulatory criteria for sale and use in
the UK and Europe.

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1.

Engine layout and design:

Figure 1- Engine aligned with mounting blocks.

Figure 2 - Flexible coupling connected to the crankshaft and input shaft.

3. Service supply details:

Table 2 - Purchasable Parts with Identification Codes

Part Name Identification Code

4. Testing and quality assurance:

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