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Chuankai Sun Personal Portfolio Address: 1292 A Blue Hills Ave, Bloomfield, CT, 06002

Email: chuanks@g.clemson.edu Cell: +1 (864) 907 9180

All examples below are based on published info or sketch work.

X Mini Go Kart (Liquid Piston, Inc) Feb 2016- Apr 2016

Designed all of the components including drivetrain, mounting, chain system, etc of the Go Kart I bought (Figure 1). Co ordinated the machining of the components and built the Kart, and tested the Xmini on Go Kart for the first time of Liquid Piston

History. Took the X Kart for the MIT demo and it is fabulous to public.

Figure 1 Xmini on Go Kart

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X Mini Sealing (Liquid Piston, Inc) Jan 2014- Jan 2016

Initial creative design of U-cup face seal and following revisions, which gave nearly perfect geometric sealing (Figure 2). Cooperated with manufacturing (Figure 3 Right) designed all the machining tooling and process for face seals (Figure 3 Left). Improved conformable face seal design and leakage pattern analysis for better sealing (Figure 4).

Figure 2 Cross section of XMv3 U-cup face seal (rignt) and previous XMv2 internal face seal (left)

Figure 3 Machining Tooling for Face Seals Figure 4 Conformable Face Seal Design Study

Combustion Efficiency Improvement (Liquid Piston, Inc) Jan 2014- Jan 2016

Designed quiescent (Figure 5), high speed chamber (Figure 6), side & flat chamber (Figure 7), including size, compression ratio, packing with sparkplug, Kistler pressure sensor, thermal couple, etc.

Cooperated with Quartz supplier to design the clear cover for combustion high speed vedio (Figure 8). See the Vedio Link: http://liquidpiston.com/technology/x-mini-gasoline/

Did housing thermal expansion FEA for rotor and housing clearance check, volume change and CR dynamic measure (Figure 9). Did benchmark with one 30 cc piston engine intake and exhaust timing and modified the rotor port timing for better breathing and

decreasing EGR for improving combustion efficiency (Figure 10).

Figure 5 XMv3 quiescent combustion chamber Figure 6 XMv3 high speed combustion chamber

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Figure 7 Side & Flat Chamber Design Figure 8 Quartz Cover Combustion Vedio Pic

Figure 9 Housing Thermal Expansion FEA Figure 10 Intake and Exhaust Porting and Flow Area

Reducing Heat Transfer in Chamber (Liquid Piston, Inc) Jan 2014- Jan 2016

Cooperated with MAO alumina supplier, chrome coating supplier for coating to reduce heat transfer and better wearing properties. Designed all the masking tooling for covers, rotors, (Figure 11 First) and machined all the related parts using lathe and milling

machine (Figure 11). Designed heat flux sensor mount in chamber.

Figure 11 Masking Tooling for Cover

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Xmini Cooling (Liquid Piston, Inc) Jan 2014- Jan 2016

Designed several concepts of cooling housing, including fin housing (Figure 12) and foam housing, most recent fin housing (Figure 12 Left) allow XMv3 to run steady state at 10,000 RPM, WOT with air cooling.

Released all covers and housings to China and did inspection, coating, re-machining and testing. (Figure 12 right & Figure 13)

Figure 12 XMv2 (left), XMv3 Most Update(middle), XMv3 Previous (right)

Designed several concepts of cooling rotor like foam insert rotor (Figure 13 Right) and rotiator (Figure 13 Left and Middle), etc. Thermal FEA design weight and heat transfer optimization (Figure 14), balancing, manufacturing feasibility (Figure 13 Middle),

heat transfer modeling.

Figure 13 Cooled Rotor Design (Rotiator and Foam Insert Rotor)

Figure 14 Rotiator Fin Thermal and Weight Optimization

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Designed all XMv3 front and back cooling shroud (Figure 15) revisions with help of CFD verification. 3D printed releasing and tracking.

Figure 15 Cooling Shroud Design Example

Xmini Breathing (Liquid Piston, Inc) Jan 2014- Jan 2016

Designed the hole crankshaft breathing strategy and did FEA stress improvement due to the previous stress failure (Figure 16 Left). Involved in Xmini breathing strategy design from the beginning (Figure 16 Right). Designed root blower supercharger for intake breathing (Figure 17). Designed exhaust manifold and exhaust shroud for exhaust (Figure 18).

Figure 16 XMV3 Breathing and Cooling Cross Section and Hole Crankshaft FEA

Figure 17 Root Blower Supercharger Concept Figure 18 Exhaust Shroud & Exhaust Manifold

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Mechanical Implement (Liquid Piston, Inc) Jan 2014- Jan 2016

Designed the X geometry, rotor shape, housing shape, window shape in CAD (code is generated by the President). Designed the speed increaser with planet gear system (Figure 19 Left). Designed the X engine gear system, with gear load calculation, gear stress hand calculation, FEA gear bending stress and surface

stress and so on. I set up the FEA tutorial gear study for LPI (Figure 19 Middle and Right).

Figure 19 Gear System Design and FEA

Testing Bench Improvement (Liquid Piston, Inc) Jan 2015- Mar 2015

Re-designed the dyno assembly including dyno mount, engine mount, cooling supply system, cooling shroud, exhaust system, drivetrain, torque transducer and so on all by myself, bought all the related stuff, organized machining and rebuilt the dyno. (Figure 20 Left Upper is Previous Design, Figure 20 Others Pictures Present Design)

Designed the mobile dyno CAD and exhibition mobile dyno.

Figure 20 Previous Dyno Assembly (left upper first pic) and Updated Dyno Assembly (others)

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Real Time Residual Gas Fraction Prediction (CUICAR, Clemson University) Oct 2013- Dec 2013

Team leader in calibrating a GT-Power model with 3.6L Chrysler Pentastar engine and get intake, exhaust pressure, fuel equivalence ratio and compression ratio to predict RGF, the GT-Power, Simulink model and testing data matched up well.

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Modeling and Control of Turbocharged SI Engine (CUICAR, Clemson University) Oct 2013- Dec 2013

Team leader in building a 4 cylinder SI turbochaged SI engine in GT-Power and use PID control to control the intake manifold pressure and wastegate with different throttle inputs (Figure 21).

Bulit Simulink relationship between turbine mass flow and intake manifold pressure, intake manifold pressure and throttle and wastegate. If the intake manifold pressure is higher than 1 bar which is the high pressure case by our define we will set wastegate fully open and we will control the intake manifold pressure with throttle using the look up table. If it is low pressure in which case intake manifold pressure is lower than 1 bar, we will set the throttle fully open and control the wastegate using the look up table to control the intake manifold pressure (Figure 22).

Figure 21 4 Cylinder Turbocharged SI Engine with PID Control of Wastegate GT-Power Model

Figure 22 Switch Scheme for Lookup Table Simulink Model

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Fuel Economy Test (CUICAR, Clemson University) Aug 2013- Dec 2013

Federal test procedure (EPA 75), highway driving schedule, high speed driving schedule, air conditioning driving schedule, cold temperature driving schedule fuel economy test on the chassis dynamometer for the BMW 535i with AVL fuel system (Figure 23).

Did emission test at the same time with CAI emission bench.

Figure 23 Fuel Economy Driving Cycle Test on Chassis Dynamometer

Fatigue Proving Ground Test (CUICAR, Clemson University) Aug 2013- Dec 2013

Set up Accelerometers, strain gages, string potentiometers, roll rate sensors to get data and test the vehicle on coarse road and study the run to run variability and fatigue (Figure 24).

Figure 24 Fatigue Test of Dune Buggy

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Four Poster Road Simulator Test (CUICAR, Clemson University) Aug 2013- Dec 2013

Road simulator test of the same dune buggy with nearly duplicate test track response measurements (Figure 25).

Figure 25 Road Simulator Test

NVH (CUICAR, Clemson University) Aug 2013- Dec 2013

Tested a Mazda CX-7 noise and vibration. Accelerometers are mounted on the right front and rear spindles, right rear seat track and steering column. A microphone is mounted between the two front seats. The vehicle is tested at steering wheel impact, idle, impact strip, rumble strip, rough road, coarse road, smooth road and typical road.

Figure 26 NVH Test Showing the Resonance Frequency

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Deep Orange 5-General Motor (CUICAR, Clemson University) Aug 2012- Jun 2013

Designed a urban solution module vehicle concept for selected target customers with certain life styles (Figure 28&29 Left). Designed Chevy gro and Chevy institution packaging (Figure 27) and did BIW (Figure 29 Right), CNC hybrid powertrain design. Did cost of ownership study, business model design, interior concept design, weight study, cost analysis, brand analysis, Gen Y/Z

and urban mobility analysis.

Figure 27 Chevy Gro and Institution Concept

Figure 28 Chevy Institution Build in Module Concept

Figure 29 Chevy Gro External Module Concept

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Project Management Electrified Dune Buggy Retrofit (CUICAR, Clemson University) Aug 2012- Jun 2013

Retrofit the gasoline powertrain dune buggy to an electrical one for a hypothetical recreational facility where public users would rent the vehicle for sporting use or for a research institution that may use the vehicle as a test bed to conduct experiments.

AHP analysis to focus on safety, range and acceleration as our target (Figure 30). QFD analysis to get the system target (Figure 31). TRIZ to find the general problem for each target and find the general and specific solution with help of mind mapping (Figure 32). Project schedule plan to organize the process. Picked DC motor instead of AC motor and picked LiFePO4 battery and motor controller, DC-DC converter and reduction gear. Calculated the performance output like acceleration, max speed, range of time, etc, with different motor characteristics (Figure 34)

and designed the preliminary CAD of the packaging (Figure 33). Refined concept with FMEA. Did BOM of the concept, and benefit analysis was conducted to see the cost, revenue and break event

time. In the end, SWOT analysis was used to final analysis the concept.

Figure 30 AHP Feature Priority Analysis Figure 31 QFD System Target

Figure 32 Mind Map for TRIZ Solution Figure 33 Mind Map for TRIZ Solution

Figure 34 Chevy Gro and Institution Concept

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Device to Automatically Adjust Automobile Temperature (CUICAR, Clemson University) Aug 2012- Jun 2013

The system will automatically turn on/off air conditioner at set up temperature, did the labview control (Figure 35). see vedio https://www.youtube.com/watch?v=4O8r1jKQLvo

Figure 35 Labview Setup for Temperature Control

Additional Machining Part (Liquid Piston, Inc)

Figure 36 Double Fuel Injector Bracket

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Reference:

[1] D. Littera, M. Nickerson, A. Kopache, G. Machamada, C. Sun, A. Schramm, N. Medeiros, K. Becker, N. Shkolnik, A.

Shkolnik, Development of the XMv3 High Efficiency Cycloidal Engine, JSAE 20159719 / SAE 2015-32-9719

[2] Alexander Shkolnik, Daniele Littera, Mark Nickerson, and Nikolay Shkolnik , Development of a Small Rotary SI/CI

Combustion, 2014-32-0104

[2] Website Links

http://liquidpiston.com/technology/x-mini-gasoline/

http://www.foxnews.com/leisure/2014/11/24/compact-rotary-engine-is-petite-powerhouse/

http://www.wired.com/2014/11/tiny-engine-make-leaf-blowers-sound-less-like-jet-engines/

http://www.mfg.com