Download - Next Generation FSAE Drivetrain - ShoutWiki
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Next Generation FSAE Drivetrain
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Project Goals/Purpose
• Future Involvement in FSAE Competition
• Unique and Innovative Design
• Complete Engineering Analysis
• Create Expo Showcase
• Use and Impart Project Learning
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General Information
• Reverse engineer existing engine
• Understand internal engine operations
• Apply knowledge to new design
• Repackage KTM 540 SX engine
• Determine drivetrain configuration
• Explore engine mountings
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540 Engine Cross Section
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Transmission Gear Train
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Transition to Next Gen from KTM Parts
• Apply project learning from original KTM design
• Apply FSAE rules to New Design
Design Goals
• Compact overall package
• Innovative configuration
• Light weight and powerful
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Integrated KTM Components
• Transmission
• Clutch
• Crankshaft
• Piston and
Connecting Rod
• Cylinder Head
Assembly
• Balancer Shaft
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Differential Selection
• Limited Slip Differential Features
Drexler Differential Taylor Differential
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Ring and Pinion Drive
• Torque Requirements
~3000 (lb-in) and 1000 (lb-in)
• Ring and Pinion Options
– 4:3 and 3:1 configuration
• Mounting the gears in the case
• Bearing Stresses/Tolerances
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Concept Layout
3 to 1 Ring & Pinion Configuration 4 to 3 Ring and Pinion Configuration
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Final Concept Layout
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Subsequent Case Design
• Engine Case Integrity
• Timing Chain Routing
• Gearing Stresses
• Ring and Pinion Interface
• Engine Cooling and Lubrication
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Questions or Comments?