Formula SAE Flow Testing Device Team members: Keith Lundquist Long Dang Adam Barka Vu Nguyen Jasper Wong Industrial Advisor: Academic Advisor: Evan Waymire, PE Chien Wern, PhD Long

Outline Introduction Design Requirements Top Level Design Background – Need – Mission Statement Design Requirements Top Level Design Design Analysis Final Design and Prototype Verification Conclusion

Background Formula SAE® Student Design Competition Open-wheel, Formula style race car Engineering + Business Long

Need Flow coefficients for 1-D simulations (valves and orifices) Direct comparison between iterative designs (head loss/system curves, velocity profiles, misc. design validation)

Mission Statement Design and build a device capable of measuring: Flow coefficients for the intake, exhaust, and throttle valves at various open positions Mass flow through the intake manifold and exhaust ductwork.

Design Requirements Capacity 160 cfm @ 28 inH2O Repeatability +/- 5% Manufacturability In-house Cost  $1,500 Noise level < 95 dB Easy to use, maintain, and upgrade Adam

Top Level Design

Design Analysis Finite Element Analysis Computational Fluid Dynamics Numerical Analysis

Final Design and Prototype

Final Design and Prototype

DAQ and Control

Verification Noise level < 95 dB 92 dB Manufacturability In-house Yes Easy to use, maintain, and upgrade Yes

Verification

Verification Volume flow rate capacity 81 cfm @ 28 inH2O Air box losses much higher than analysis predicts Possibility of leakage Easy to modify/upgrade (modular design) Repeatability has not been verified Calibration equipment in transit

Conclusion A complete prototype flow testing device has been designed and manufactured. Further testing will be completed by VMS and Capstone team members. Lessons learned Engineering design process Design for manufacturing Teamwork Time and budget constraints

Questions? Long + Adam