Elio engine makes like Justice League, assembles!

Elio Motors has been keeping us updated with its latest engine prototype news for some time now. This week, we learned the first prototype has been assembled.

The latest “Tech Talk” e-mail from the makers of the proposed three-wheeled commuter car showed several photos of the engine’s top and bottom ends fully assembled with pistons, camshaft, and all. The e-mail said engine developer IAV began assembly of the engine prototype this week so the testing phase can continue.

“Entering the testing phase is one of the most crucial portions of the entire engine development process,” the e-mail said. “To this point, we have used sophisticated simulations to model how the engine will perform in a variety of driving conditions. While we use the most advanced simulation tools available in the auto industry today, there is still nothing quite like having a physical prototype and putting it through a battery of tests on the dynamometer.”

Calling quality and customer satisfaction “essential to winning today’s highly discerning customers,” Elio said there was “no margin for error” in any new vehicle. That’s why Elio said it will put the engine through a rigorous test phase, both to test its mechanical integrity and see if it is capable of living up to data generated during computer simulations in the initial design phase. As we’ve covered extensively in these pages previously, Elio’s goal is for its car to achieve an EPA rating of 84 MPG highway. Dyno testing of an actual engine prototype is the first concrete step toward proving whether that will be a feasible target with the engine as currently designed.

o    Among the scheduled testing, according to Elio Motors: First-level emissions testing – Obviously, it is impossible to build a zero-emission internal combustion engine, but our goal is to be as environmentally friendly as possible. Testing emissions at this phase will allow the engineering team to make adjustments if needed.

o    Burn Rate/combustion characteristics of the combustion chamber – Fuel efficiency of up to 84 MPG is one of Elio Motors’ four “Must Haves.” But, Elio Motors also wants to ensure that the vehicle will have performance characteristics that meet customer demand for speed and power. Testing on the dynamometer will verify if the burn rates, knock resistance and combustion efficiency is conducive to achieving the level of efficiency for which the engine is designed.

o    Timing of the valve train – Another important factor in determining overall engine performance and efficiency is the timing of the valve train. If this system is not in sync, it will cause a detrimental impact on overall fuel efficiency.

o    Friction – Long-term durability also is important to overall customer satisfaction. Too much friction in the engine can cause wear and tear and impact engine life.

When we last shared an Elio “Tech Talk” about the prototype engine, the company spotlighted our post on its Facebook page. In the comments to that post, we asked Elio if its fans and reservation number-holders might get to see video of the prototype engine running on the dyno as a sort of early Christmas present. At this rate, I’d say that might actually happen. We’ll look forward to that.

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