Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski William Mehnert

Overview Project Objectives Project Review Future Considerations Testing and Instrumentation Lab Testing Equipments Instrumentation Setup Hardware Selection Hardware Modification Software Modification Design of Experiments Nugget Chart Gantt Chart

Project Objectives Provide a control unit that will allow a gasoline engine to operate on E85 without sacrificing fuel consumption, performance, and emissions by optimizing operation parameters on the fly to create an efficient flex fuel option. Develop and execute testing procedures to accurate assess and compare the performance of the engine operating either gasoline, E85, or any other blend.

Project Review Phase I –Conceptual Design/State of the Art Review Phase II –Technical Analysis (Ignition Timing) Phase III –Final Design Proposal and Budget Phase IV –Order Components, Sponsorship, Integration of Major Components, –Testing preparation and accommodations

Future Considerations Completion of Prototyping and Testing Build a strong foundation for future design groups and Formula SAE competition groups Useful resources that can be utilized in lab experiments Optimization of programming for better execution “Plug and Play” design for easier installation in factory vehicles –Install only EGT and Flex Fuel sensor –Interrupt and adjust Ignition Timing and Fuel injection Reduce the size of the unit

Testing and Instrumentation Testing requirements –Ability to move the testing space to the testing facility –Placement of data acquisition equipment on the testing space –Ability to easily remove the data acquisition equipment –Knowledge of dynamometer and gas emissions equipment –Prediction and verification of dynamometer results

Lab Testing Equipments Sensors –Gas flow and air flow meter –Intake pressure sensor –Cylinder pressure Emissions Analyzer Dynamometer Data Acquisition component

Instrumentation Setup Sensors –Flow measurement Fuel measurements –Temperature Sensors Exhaust Gas Temperature Coolant temperature Intake temperature –Pressure Sensor MAP –Crank Angle Sensor –Oxygen Sensor Measure the amount of Oxygen at the exhaust Correct the amount of fuel –Wideband Sensor A/F ratio –FlexFuel Sensor Fuel blend –Throttle position sensor

Hardware Selection Megasquirt II v.3.0 –Allows for ignition and fuel adjustments based on RPM, Throttle Position, Coolant Temperature, Air Temperature, and Air density –Contains prototype area to build custom circuits Innovate Wide-band Oxygen Sensor –Most cost effective unit on the market –Output directly into the Megasquirt unit

Hardware Selection K-Type Thermocouple (EGT) GM Flex Fuel Sensor Megasquirt Stimulator v.2.2 –Allow testing of feedback functionality without risk of damaging critical engine components Sponsorship by

Hardware Modification Flex Fuel Sensor –Added resistor to circuit Exhaust Gas Temperature Sensor –New separate circuit built in prototype area of board

Software Modification Open source Added gauges Added features for data acquisition Need to add closed loop control for EGT feedback

Design of Experiment PHASE ONE: Sensitivity Analysis Open loop testing –Timing Testing for –Horsepower/Torque –Emissions –Fuel swap and A/F adjustment Testing for: –Horsepower/Torque –Emissions

Design of Experiment PHASE TWO: Sensitivity Analysis and Optimization Closed loop testing –A/F ratio Optimization of target values –EGT Optimization of ignition timing Optimization of emissions

Design of Experiment PHASE THREE: Results and Conclusion E85 Performance Map Comparison Matrix Recommendations for future studies Future of E85 as a reliable alternative fuel source

Nugget Chart

Gantt Chart

Thank you Any Questions?

Reference Internal Combustion Engines, C. Ferguson and A. Kirkpatrick, second edition