SHARC - System for the Hybridization of All Road Cars

This is my entry to the 2009 GreenTech Expo. With it, I won second place in the competition. Pictured above is a model of a chassis and powetrain with seats and a steering wheel to make it look somewhat like a car. A description of how it works follows. 

Mission and Mechanisms:

A major source of pollution today comes from cars. In 2006, the United States consumed 174,930 million gallons of fuel [Bureau of Transportation Statistics]. Burning one gallon of gasoline produces 20 pounds of carbon dioxide [Environmental Protection Agency]. Therefore, in 2006, our nation released 3,498,600,000,000 pounds of carbon dioxide - a greenhouse gas. 

A huge number like that cannot be meaningfully lessened by a slow adoption of expensive hybrid/plug-in cars. What is required is SHARC. SHARC is a cost effective, flexible, and robust system that can reduce emissions and gas usage when used on the world's car fleet. 

SHARC works by replacing a car's unpowered wheels with special wheels that have built in motors. These motors are powered by a trunk mounted battery and propel the car without the gasoline engine. Minor powertrain modifications are necessary for both the gasoline engine and electric hub motors to not interfere with each other. 

Retrofitting a manual transmission, rear-wheel-drive car with SHARC is show in the video below:

SHARC Components:

• Motor – wheels that are unpowered are replaced with new wheels that contain electric motors in their hubs. These motors can either freewheel, allowing the gas engine to propel the car, or can use electricity to propel the car. Also, Regenerative braking is possible with these wheels. Pictured is the Michelin E-Wheel which is an example of this technology that will soon be available to manufacturers. 
• Batteries installed in the trunk give the car approximately 30-40 miles of travel under electric only power. NiMH, Lithium ion, Lithium polymer, and supercapacitor technology can be used. These batteries can be recharged through regenerative braking or being plugged into the power grid. The controller is circuitry that optimizes the usage of the motors, gas engine, and locking hubs with regards to maximizing fuel economy and reducing emissions. A range of batteries will be available to satisfy space, capacity, and price requirements. These batteries will also power the accessories like the radio, power windows, air conditioning, etc. 
• Powertrain Modifications - These disconnect the engine-powered wheels from the engine, allowing the hub motors to propel the car with a dormant gasoline engine. Manual transmission cars will require a mechanism to lock the clutch in the engaged or disengaged position. Automatic transmission cars require the engine-powered wheels to be installed with commercially available locking hubs. 4wd vehicles require a brake locking mechanism which allows the engine torque to be transmitted to the ground instead of the car. Because cars are becoming more and more computerized today, many of these modifications can be done through software by reprogramming the engine's control unit. 
• Electric Heater (optional) - an electric heater is necessary for full accessory function in cold climates. 

SHARC Mileage:

If the rechargable battery provides 30 miles of gas-free power, then a 60 mile trip only uses half the gas. Trips under 30 miles (or the battery range) require no gas at all. Example car is the 2008 Chevy Malibu which gets 30mpg combined [www.fueleconomy.gov] 

The Bureau of Transportation Statistics reports that 75% of American commuters travel less than 40 miles per day. Therefore, fitting all cars with 40-mile-range SHARC systems enables us to reduce gas usage by over 75%.  

Emissions:

Because SHARC has the ability to increase gas mileage, it can decrease emissions. Below is a chart of how many pounds of carbon dioxide are not emitted per day if an average car was retrofitted with the SHARC system. 

250,852,000 vehicles registered in 2006 and if 25% of them used SHARC with 20 mile battery:

• (62,713,000 cars) x (1.163 gal/day) x (365 days) = 2.6621 x 10^10 gallons saved per year
• (62,713,000 cars) x (23.256 lbs CO2/day) x (365 days) = 6.01 x 10^11 pounds CO2 not emitted per year

We used 1.7493 x 10^11 gallons of gas in 2006 which equates to 3.4986 x 10^12 pounds of CO2. With the 25% adoption and 20 mile battery as detailed above, this leads to a 16% reduction in emissions and gasoline usage. This small but noticeable dent in our addiction to gasoline and it is only the beginning. As fuel economy rises, battery capacity increases, and SHARC adoption increases emissions will dwindle and gas would be consumed even more frugally. 

Charging Qualms?

Some say that electric powertrains simply move the cost and emissions that are associated with gasoline to the power plant. However, electric powertrains are much more cost effective than gasoline ones. Below is a calculation of the costs to drive one mile in the Chevy Volt and the similarly sized Toyota Corolla. 

The above calculation did not factor in fluctuating gas prices. Electricity prices do not fluctuate as much as gasoline; they only fluctuate when demand is less during the night. SHARC vehicles could thrive on cheap nighttime electricity. The electrically powered Chevy Volt is clearly more cost effective than the gasoline powered Toyota Corolla.

Others may argue that SHARC's electric powertrain simply moves the pollution of gas powertrains to the smokestacks of powerplants. However, gasoline is not a renewable and environmentally friendly power source when compared to 25% of our nations power plants which are hydropower, nuclear, wind, solar and biofuel powered. Also, power plants are much more geared towards efficiency and emissions control than cars. State of the art scrubbers already reduce many emissions and clean-coal technology is on its way to completing the emissions removal process. This is a stark contrast to our car fleet which has wasteful engines and decaying catalytic converters. Also, we do not import electricity. SHARC adoption will reduce our dependence on foreign oil because electricity comes from our own resources. 

Why SHARC?

SHARC easily converts normal cars into hybrid cars with small and cheap modifications. It can be installed by a qualified mechanic or any car savvy person. Installation provides a Chevy Volt-like car for everyone. 

The entire SHARC system is low cost. Currently, converting a car into an electric car costs between $5,000 and $10,000 [howstuffworks.com]. A Chevy Volt, which is similar to a SHARC fitted car, will recieve $7,500 in tax credits. So assuming the worst-case scenario - a SHARC installation costing $10,000 - tax credits will reduce it to $2,500. This is in line with current hybrid upgrades like the Chevy Malibu Hybrid, Saturn Vue Hybrid, Toyota Camry Hybrid, etc. As tax credits go down, mass production of SHARC components will keep the cost low. 

Installing SHARC also reduces wear on the gasoline engine because it will remain off during some driving. Electric motors are not prone to wearing down because they have only one moving part. For example, Jay Leno's 1909 Baker Electric is still running today [nytimes.com]. 

SHARC technology can also be integrated on manufacturer's assembly lines and offered as an option to consumers. SHARC can increase the average fuel economy of automaker's cars and allow them to more easily meat the CAFE standards. 

Works Cited [opens in same window]

Manatee

This is my Lego manatee for my science extra credit. My favorite part is how the head rotates completely using right-angle gears and an axle that goes the length of the body. I'm not sure if that got me any extra points though...

Space Shuttle

I was very impressed with the official knex model of the space shuttle. As usual though, I wasn't content with following their instructions - I wanted to see what I could come up with. I also wanted to do something different, give the shuttle model a more inspirational pose instead of being a couch potato on a knex launch pad. I made a stand which holds it on an angle and shows the shuttle soaring through the air.

Overall a bit too colorful for NASA's crowning achievement but I only had standard-colored knex pieces. Some things you have to leave for the pros...

Year Made: 2005

My Room

I have always shied away from buying furniture; the allure of making it by hand is more appealing. Although these aren't Lego creations, they follow my principle of making something for either an aesthetic or practical purpose. I am proud of these designs because I didnt have to invest in new desk; instead I used $5 worth of knex from a garage sale.

This was my poster for my school's National Engineering Week contest. It got honorable mention. I suppose the judges appreciate actual effort going into a poster more than printing out a bitmap.

However, I engineered the knex models to add more space and versatility to my workspace. The table in front of my computer has my food. My grandmother insisted that I always should eat at the table and I insisted that I eat in front of the computer. Therefore, I made my own table for my room.

I needed more space to hold my things, my phone, and my pens. I made a bridge in between my desks to add more space, threw together a mount for my phone (the knex piece emulate nails onto which my phone could hang from), and a tray for my pens/pencils. Both structures have plenty of triangles (one of the strongest shapes in nature) allowing them to each hold many books and efficiently transfer their loads to the ground or adjacent desks.

Microscope

For those people in Mrs. Henry's 04-05 class, this is a familiar model. I don't like it so much (because this is not what a real microscope looks like) but my mom likes it. Ironically it got me a hundred on my science project.

This model does everything a real microscope can do except magnify. the body tube moves up and down and there are actual fine and coarse adjustment knobs. These knobs move the body tube at different rates. The fine adjustment knob moves the tube through gearing but the coarse adjustment knob is a large gear that turns the fine adjustment knob many times. There are stage clips and nosepiece work as well. I solved the problem of a sliding body tube by using a worm gear (this allows high-torque output from one end but not input from that same end). Therefore the body tube only moves through the input of the knobs and not gravity. Furthermore, the rack and pinion arangement I used were also essential because it converts rotational movement into lateral movement. There is a closeup on the worm gear and rack and pinion gear above.

Artist

This is one of my mother's favorite models because she paints. The artist can be seen painting a house. I got this idea from one of my idea books but the design of the hat and pallet were my idea. I made a similar model when I was living in New York bet it got destroved when I moved to New Jersey.

The entire creation, from the painted picture to the model, has a blocky pixelated feel, addingto its lego-ness.

(year made:199something, recreated:2003)

Helicopter Truck

I got the idea for this truck from a lego magazine. Obviouly it is a mini model. The helicopter can lift off the trailer and can be securely fastened on to it. The rotor on the helicopter spins.

(year made: 2004)

2 Wheeler

I designed this model to test a concept: to see weither a car can run on two wheels (I conveniently had only two big wheels lying around). I partially succeded: the cockpit keeps on spinning with the wheels. In theory, this model would have a heavy weight in the cockpit to prevent it from rolling with the wheels. It can comfortably seat one lego person.

However, the creators of Star Wars had more sucess than me while making the Hailfire droid as pictured below.




(year made: 2004)

SpyRunner

This plane is called the SpyRunner (don't ask me why because that's what is says on the rudder). There is a secret compass, engine compartment, and navigator's compartment. The reason I made this model is because it demonstrates that I can use a certain technique (attaching the wings to a right angled plate). I saw this technique being used in a model from a Lego magazine.

(year made: 2004-2005)

James Bond Car

This is one of my all-time favorite model. More appropriately named the James Bond truck, is one of those models that people seem to like. It stresses a very important concept of adding new and interesting features : if the model is going to be awesome then it must do something (this model does a lot of things!).

The James Bond car took me several months to make. This is because I was constantly improving it. When I first built it, it only had the AA laser and a whimpy turbine at the back. Now its packed with gadgets including missiles, special slide up doors (gull-wings are so 20th century) doors, side grenades, machine gun, mini-cruse missile, and oil slicks. A gatling gun revolves around when the car is rolled across the floor. This is because it's axle is attached to the car's spinning rear axle through a rubber band. Feel free to click the thumbnails for a better view of the gadgets.

(year made: 2004-2005)

Creating Lego Models

The most frequent question I am being asked by friends and family is how do I make such amazing models? My answers to their question are:

>Always think and formulate ideas for new models
>Always improve current models
>Most importantly, practice!!!

Always think of ideas for your new models - One should keep on thinking even if it gets that person nowhere (it's better than not thinking at all). Look through books, magazines, and the internet for ideas. One will always find something. I usually prefer futuristic concepts (Popular Science, concept cars) because these are very motivational. Then one can start with replicas of classic cars, famous landmarks, airplanes, etc... One can even test out their own concepts (like projectile launchers, rubber band suspension, etc).

When a model is first made, it is never perfect. However one might have spent hours making it. This should not discourage any Lego builder rather the person should take a well-deserved rest and improve the model. This process might have to be repeated many times till the model is close to perfection.

And finally... the most important aspect of making models...practice. The models I make now are the result of twelve years of lego building. When I think of my previous models, I can remember blocky shapes with very little details and overly colorful models that would be classified as poor by my current building standards. I firmly believe from my twelve years of Lego building that it enhances one's spatial abilities and creativity. So the sooner a child gets involved with Legos the better will be his/her Lego experience. According to my mother, my father introduced me to Lego toys since the age of 1 and I have been playing with them ever since. Because of him, I have a stack of Lego magazines over six inches thick (from the year 1996).