P13222: FSAE Turbocharger Integration Thursday, November 8 th, 2012 Kevin Ferraro, Phillip Vars, Aaron League Ian McCune, Brian Guenther, Tyler Peterson Detailed Design Review

Agenda Customer needs review System architecture Specifications overview Review of compliance with requirements Updated risk assessment Testing Plans Bill of Materials Timeline/Schedule

Customer Needs Review Customer Need # ImportanceDescription CN15Overall Horsepower and Torque Gains CN25Optimized ECU Map for Best Performance CN35Consistent Engine Performance CN45Necessary Engine Internals are Included with System CN54Adequate System Cooling CN64Sufficient Dyno Testing and Validation CN74Optimized Turbo Size for Application CN84Meet FSAE Noise Regulations CN93Quick Throttle Response CN103Easy to Access in Car CN113Compact Design in Car CN123Fit Within Constraints of Current Chassis CN132Easy to Drive CN142Drivetrain Components Designed for Power Increase CN152Design for Intercooler Location (if required) CN161Readily Available Replacement Parts CN171Simple Interface with Current Engine CN181Maximized Use of Composite Material

Specifications Table

System Architecture Induction Turbocharger Boost control Engine Exhaust system Mounting

Induction SpecificationValueComplianceVerification Mass air flow>= 50 g/sCFDPressure measurements Restrictor Diameter <=20 mmDesignMeasure Plenum Volume>=1000ccCAD, 3D modelingVolume measurement Air temperature reduction >= 50°F CFD, heat transfer analysis Thermocouple measurement Intake manifold pressure range 0-30 psi Design, component selection Component pressure capacity will be tested during dyno data collection Throttle Modulation Near linear, Throttle position vs flow CFD analysisDynamometer measurement

Spike Throttle

Intercooler CFD and GT-Power Simulation Inlet, hot side: max spec temp from turbine outlet Inlet, cold side: ambient environment N=number of cells Thickness Width

Turbocharger SpecificationValueComplianceVerification Peak Power Output 60 hp, 45 ft*lbs GT Power simulationDC Dynamometer measurement Peak efficiency Efficiency maps, GT Power simulation DC Dynamometer measurement: Fuel consumption vs. power Pressure to Actuate Wastegate 20 psiPurchased partTest stand measurement Max Temperature of Turbo <800°F Assumption: no modification from production part Thermocouple measurement Supplied Oil Pressure 170 kPa (24.7 psi) Tapping into oil return line of engine Oil pressure sensor, tapped into oil return line Mass flow rate, compressor >=40 g/s Compressor efficiency map DC Dynamometer measurement Mass flow rate, turbine >=100 g/sTurbine efficiency map DC Dynamometer measurement

Turbocharger

Boost Control SpecificationValueComplianceVerification Peak Power 60 hp, 45 ft*lbs GT PowerDC Dynamometer measurement Pressure to actuate wastegate 20 psiPurchased partBench-top testing Maximum Boost level 30 psiSolenoid selection, flow rate calcs Manifold air pressure sensor reading

Boost Control

Exhaust System SpecificationValueComplianceVerification Fit in the Car1CreoSolid modeling Efficiency of turbine>40%GT-PowerDyno Testing External Temperature <800 °FGT-PowerDyno Testing Bend Radius3 inCreoSolid Modeling

Header Design

GT-Power Simulation

Mounting System SpecificationValueComplianceVerification Turbo axis of revolution orientation Normal to gravity, ±10° 3D CADVisual/Inspection Oil outlet directionParallel to gravity, ±35° 3D CADVisual/Inspection Connections to chassis Compliance for CTE mismatch, vibration Design and analysisAssembly, testing in operating conditions

Mounting

Risk Assessment IDRisk ItemEffectCause Likeli hood Severi ty Impor tance Action to Minimize RiskOwner 1Poor Fuel EfficiencyLow Fuel Economy Score Engine not tuned properly for endurance 133 Create separate fuel maps for each individual event Powertrain Engineer 2High Car CGReduced Cornering Ability Turbo location not optimized 122 Turbo placed within crash structure, allows for lowest placement possible according to rules Chassis Engineer/Structures Engineer 3Insufficient Oil Flow Blown Turbo/Short Turbo Life Poor analysis of oil pressure source 236 Test oil pressure and flow of source prior to turbo implementation, follow manfr's recommendations on oil supply Powertrain Engineer 4Thermal Management Chassis, engine, seat, or fuel over allowable temperature Unexpectedly high heat generation 212 Analyze chassis airflow and design for cooling, design in flexibility for additional cooling mechanisms Chassis Engineer/Thermal Engineer 5Engine VibrationTurbo Mount Failure Insufficient structural analysis 122 Design with vibration in mind. Verify components are constrained properly Structures Engineer 6Thermal Expansion Stresses Additional stresses on mounting components Thermal CTE mismatch between exhaust components and mounting components 122 Design compliance into mounting system to relieve thermal expansion stresses Thermal/Structures engineer 7Improperly Tuned Engine Poor overall engine performance Lack of time to properly tune engine on dyno 236 Schedule must include plan to have plenty of engine testing time on the dynomometer Powertrain Engineer 8Lack of Available Space in Chassis Heavy plumbing and inefficient routing Not all locations analyzed for optimal routing 212 All project members agree with location and plumbing plan prior to implementation Chassis Engineer/Structures Engineer 9Improper Turbo Size Poor overall engine performance Inaccurate initial analysis and data acquisition 133 Use accurate and realistic parameters in engine simulation to make best selection Powertrain Engineer/Project Manager 10Welded Joint Failure Structural failure of exhaust plumbing, release of exhaust gasses Cracking/fracture of welded joints within exhaust plumbing 122 Use proper welding techniques to assure high quality weld. Mounting system not to rely on support through welded sections. Structures Engineer 11Engine FailureDestroyed Engine Overboost, internal component failure 133 Use high-performance aftermarket components, reduce friction through coatings, control boost to acceptable levels Powertrain Engineer

Testing Plans Purchasing: Ti tube Manufacturing: Throttle, plenum, plumbing Initial setup/baseline Dyno data collection, RPM sweeps: Horsepower, torque, AFR, BSFC, throttle position, etc Labview: Dyno Controller software

Testing Plans

Bill of Materials AssemblyItemQtyDescription Turbocharger Garret GT-06 1 Turbo Manifold Ti 1.5".020" wall tube 10 ft Exhaust tubing Ti bellows 1 Exhaust bellows Ti.125" thick plate 2 ft^2 Plate for manifold flanges Ti o2 sensor bung 1 Bung for engine sensor Ti thermo couple bung 2 Bung for measureing exhaust gas temperature Muffler Ti.062" thick plate 2 ft^2 Titanium plate for muffler ends Muffler packing 1 kg Fiber glass muffler packing Composite muffler can 1 6" diameter 18" long carbon fiber tube Intake Intercooler core 1 6"x9" 1.5" thick heat exchanger core Composite intercooler tank 2 Endtanks for intercooler Al 1.5".049 wall tube 10 ft Intake tubing 1.5" ID silicon hose 1 ft Intake tube joints Hose clamps 8 Intake joint hose clamps Al fuel injector bung 1 Fuel injector weld on bung Turbo Mount Mounting tube 3 ft.5" OD.035" wall 4130 tube MM-2 rod ends rod ends

Timeline/Schedule