formula sae turbocharger: problem statement: successfully implement a turbocharger system on the...
TRANSCRIPT
Formula SAE Turbocharger:
Problem Statement: Successfully implement a turbocharger system on the current WR450 single cylinder engine.
Background:
Functional Decomposition:
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:
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
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
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
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:
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):
Questions?