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Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine.

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Page 1: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Formula SAE Turbocharger:

Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine.

Page 2: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Background:

Page 3: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Functional Decomposition:

Page 4: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

1. Engine compartment restrictions from chassis2. Minimize system weight3. Cost (With or without sponsorship)4. Maintain controlled temperature5. Spares for all parts must be available6. FSAE rules and regulations

Constraints:

Page 5: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Object Honeywell Turbo University of Wisconsin FSAE (2010) Yamaha Phazer Turbo

Origin Honeywell/Garrett IHI wastegate controlled (RHF3) Mitsubishi brand turbo

Cost $643 - $5,499 (full kit for snowmobile)

Information

GT12 Family Japanese Manufacturer Kit for Yamaha PhazerSmallest produced by Garrett Running KTM 525 XC 4 stroke 500cc engine

50-130 hp range Compression Ratio - 10.4:1 Produces 136 hp (unrestricted)Recommended 400cc to 1200cc engine

size E-85 ethanol at 12 psi

Journal Bearing system max power design at 7600 RPM small, fast reacting turboOil & Water Cooling max torque design at 6000 RPM

Inducer: 29 mm min RPM for 80% max torque 5000 RPM

Exducer: 41 mm 3.5 Bar fuel pressure Trim: 50 1400cc intake plenum volume

A/R: 0.33 Max spark advance: 29 deg BTDC at 9000 RPM WOT

Turbine Wheel: 35.5 mm Turbo in series with engine dry sump

Trim: 72 No intercooler A/R: 0.43 Wiseco forged piston

Internally Wastegated

Most efficient between 0.7-1 Bar boost

Page 6: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine
Page 7: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Difficulty Source Function Specification (metric)Unit of

MeasureIdeal Value

Comments/Status

S1CN1 Engine Peak Power Output

Hp and ft-lbs

>= 60hp 45 ft-lbs

 General increase overall can also compensate

S2 CN1, 2 Intake Mass Air Flow g/s >=50  Maximize for restrictor

S3 CN1, 2 Intake Plenum Volume cc >=1000  

S4 CN3 Sensors Sensor Voltage V 5  

S5 CN1, 5, 15 Intercooler Air Temperature Reduction Deg F >=20  May not be needed

S6 CN1, 2, 5 Intake Manifold Air Temperature Deg F <=100

S7 CN1, 7, 9 Turbo Turbine Shaft RPM rpm~100,00

0Depending on turbo chosen

S8 CN1, 7, 9 Turbo Intake Manifold Pressure psi >=20

S9 CN7, 9, 13 Turbo Peak Compression by RPM (specified) rpm <=6000

S10 CN2, 3 Sensors Air Fuel Ratio Range12.6<x<

17.6

S11 CN1, 3 Sensors Manifold Air Pressure Range psi 0-30

S12CN3,4,13,

17Turbo Pressure to Actuate Wastegate psi >=20

S13 CN1,11,17 Exhaust Flow Rate g/s >=100

S14 CN8 Exhaust Noise Level dBa <110 Based on FSAE regulation

S15 CN3,5,7,16 Turbo Max Temperature of Turbo Deg F <800

S16 CN7,11,18 System Overall Maximum Weight Increase lbs <=15

S17 CN1,3,4,6 Engine Compression Ratio ~10:1 Max achievable without engine knock

S18 CN1,13 Engine Max Power Design RPM rpm ~9000

S19 CN1,13 Engine Max Torque Design RPM rpm ~7000

S20 CN1,3,13 Engine Max Spark Advance deg 40-45

S21 CN4,16,18 Funding Cost to Formula Team $$$ <100 Funding/Sponsorship will be required

Page 8: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Specifications

Peak Power Output

Mass Air Flow (Intake)

Plenum Volume (Intake)

Sensor Voltage

Air Temperature Reduction (intercooler)

Manifold Air Temperature

Turbine Shaft RPM

Intake Manifold Pressure

Peak Compression by RPM (specified)

Air Fuel Ratio Range

Manifold Air Pressure Range

Pressure to Actuate Wastegate

Flow Rate (Exhaust)

Noise Level

Max Temperature of Turbo

Overall Maximum Weight Increase

Compression Ratio

Max Power Design RPM

Max Torque Design RPM

Max Spark Advance

Cost to Formula Team

Customer

Needs

Overall HP & Torque Gains X X X X X X X X X

Optimized ECU Map X X X X X X

Consistent Performance X X X

Necessary Engine Internals X X X X

Adequate System Cooling X X X

Sufficient Dyno Testing X X

Optimized Turbo Size for Application X X X X X X

Meet FSAE Noise Regulations X

Quick Throttle Response X X

Easy to Access in Car X

Compact Design in Car X X

Fit Within Constraints of Chasssis X X

Easy to Drive X X X X X X X

Design Drivetrain Components for Power Increase X

Design for Intercooler Location X X X X X

Readily Available Replacement Parts X

Simple interface with Current Engine X

Maximize Use of Composite Materials X X

Page 9: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Qty Description

Lead (ME) 1Responsible for system integration with chassis, engine, drivetrain, and electrical components. Also responsible for management duties, and

engine calibration

Thermal (ME) 1 Responsible for heat management of the system. Will require work with FEA, Pro Engineer, Heat Transfer, and System Dynamics

Fluids (ME) 2Responsible for fluid flow analysis through each individual sub-

component of the system. Will require work with CFD, Pro Engineer, Fluid Mechanics, System Dynamics, IC Engines, and FEA

Structures (ME) 1

Responsible for structural integrity of the system. Will require analysis of vibration and stresses through use of FEA, Pro Engineer, Statics, and

System Dynamics.

*Formula SAE experience preferred for all positions

Staffing:

Page 10: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Main concern with scope is time constraints◦ Project may be used as development for future cars

rather than implementing on F21◦ Lessons learned can be advantageous in design

competition◦ Cost may be an issue without appropriate sponsorships

Specifications are reasonable, some flexible◦ Overall system gains must justify weight and cost

increase◦ Expected to set ambitious goals for top ranking car

Project staffing is realistic◦ Communication between team members will be crucial to

the quality of the project

Customer Meeting Feedback (FSAE Powertain Engineer):

Page 11: Formula SAE Turbocharger: Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine

Questions?