Lightweight Fuel Efficient Engine Package

Team Members Evan See, ME Chris Jones, ME John Scanlon, ME Stanley Fofano, EE Taylor Hattori, ME Brittany Borella, ME Project Sponsor Faculty Guide RIT Formula SAEDr. Nye P12221

Project Description In order to enhance the RIT Formula SAE team’s score at competitions, developments were needed in the following categories: Design, Endurance, and Fuel Efficiency. To achieve improvements in these scores, a well documented engine package was desired that would provide increased fuel efficiency while still providing a competitive amount of power and durability. Objective and Scope  Reduce Fuel Consumption by 60% over previous years  Provide at least 50 horsepower  Operate in ambient temperatures of 100°F under race conditions  Provide a well documented development process and test plan

Deliverables Engine Package Cooling System Engine Model and CFD Analysis Wiring Diagram Engine Maps Power Output Fuel Economy

Concept Summary Engine Selection: 2009 Yamaha WR450F Naturally aspirated Single cylinder Reliable Lightweight Fuel Selection: 93 Octane No knock at Maximum Best Torque timing Cooling System Selection: YFZ450R Yamaha ATV Radiator 160°F Thermostat External Pump Bypass System Surge Tank Design for de-aeration of top of system 30 PSI Radiator Cap

System Architecture Engine

System Architecture Cooling System Surge Tank Overflow Tank Engine Block Water Pump Fan Radiator Thermostat Bypass

Design Summary Engine Engine Model Intake runner lengths were varied in 2” increments from 6” to 10” Cam profiles and valve flow were measured at Mercury Marine Engine run on the dyno without fuel, and with a simplified exhaust and intake runner Measures frictional and pumping losses

Design Summary Cooling System Full Car CFD, showing design of front wing funneling air between endplate and chassis into ducts Orthographic detail of cooling system, showing inlet of both ducts leading to radiator

System Testing

System Testing Results Initial Dynamometer Tuning Initial fuel map with conservative timing Ignition timing advanced Knock was not noticed using 93 octane fuel, therefore engine was run at MBT

High Compression Piston Added 4% Increase In Power Hot Cam Aftermarket Camshaft Provided Up To 33% Increase In Power System Testing Results Aftermarket Additions

System Testing Results Cooling System CFD Analysis

Overall Project Evaluation State of Design Engine power peaked at 42 HP after fuel and spark tuning Intake tuning changed peak power RPM, but did not increase overall max power Performance cams and piston were evaluated in GT-Power: theoretical increase of 8 HP Components were purchased during SDII, but will be evaluated during future testing

Overall Project Evaluation Schedule MSD1 - FALLMSD2 - WINTER  Cooling System Layout  Initial Engine Modeling in GT-Power  Required Sensor List  Dynamometer Set-up  Preliminary Test Plan  Cylinder Head sent out for flow test measurements  Testing delayed due to cylinder head measurement  Finalization of cooling system specifications  Complete Engine Model in GT-Power  Testing of Engine on Dyno  Parts ordered to increase performance

Overall Project Evaluation Budget ComponentSupplierPurchasedSponsoredPriceTotal Stock for engine standSMC Metals10$50.00 ConnectorsDeutsch018$0.00 PistonCosworth20$250.00$ Cam shaftHot Cams40$80.00$ WR450 EngineeBay12$1, Cam SensorFargo Controls02$0.00 Engine SoftwareGamma Technologies02$0.00 CFD SoftwareAutodesk01$0.00 O2 SensorBosch03$0.00 Ignition ModuleBosch02$0.00 Ignition CoileBay10$25.00 Fuel InjectorDelphi05$0.00 Quart of oilMobil 106$0.00 RadiatoreBay10$45.00 Total$2,440.00

Future Project Direction Complete GUI for cylinder pressure measurement Characterize engine for brake specific fuel consumption Successfully integrate engine package with racecar Combustion analysis post- processing Design of experiments Optimization Valve train design Cooling system analysis Advanced data analysis Future GT Power Capabilities