1. Lightweight Fuel Efficient Engine Package

2. Team Introduction Brittany Borella Evan See Chris Jones John Scanlon Stanley Fofano Taylor Hattori P12221:

3. Materials Reviewed Project Description Work Breakdown Structure Customer Needs Customer Specifications Concept Development and Proposed Design Current System Design Schematic Project Plan Risk Assessment

4. Project Introduction Background: Fuel efficiency is becoming increasingly more important in Formula SAE competition scoring. In order to improve the RIT Formula SAE Race Team’s score, an engine package is desired that will be more fuel efficient while still producing a competitive amount of power. Percentage Scored (Detroit) 200920102011 Design67% 83% Cost87%89%77% Sales96%93%90% Acceleration75%80%92% Skidpad76%81%85% Autocross93%86%83% Endurance100%92%N/A Fuel20%52%60% est. Points lost 2011 DetroitGermany Design2560 Cost200 Sales77 Acceleration60 Skidpad86 Autocross2518 EnduranceN/A86 Fuel4042

5. Problem Statement: Develop a more fuel efficient and powerful engine package to be used by the RIT Formula SAE 2012 car Previous Formula SAE Senior Design Projects: – Variable Intake System – Paddle Shift System – Data Acquisition System – Engine Control Unit Project Introduction

6. Objective and Scope Entire engine package able to provide the following: – Approximately 55 horsepower – Operation in ambient temperatures up to 100°F under racing conditions – Reduction in fuel required by 60% compared to the previous engine package over a similar run Well understood and documented development process

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

8. Assumptions and Constraints RIT Formula Team previously selected a single cylinder engine – 2009 Yamaha WR450F Must comply with all Formula SAE rules – Including, but not limited to: Use provided race fuel: 93 or 100 Octane Gasoline or E85 Ethanol Spark Ignition Four Stroke

9. Work Breakdown Structure

10. Customer Needs Customer Need # ImportanceDescription Engine CN11 The engine must reduce fuel consumption when compared to the previous engine package CN21The engine must provide sufficient power output and acceleration Control System CN112The control system must provide accurate fuel delivery and measurement Cooling System CN141 The cooling system must be able to allow the engine to operate in high ambient temperatures under race conditions Documentation and Testing CN171Documented theoretical test plan and anticipated results CN181Must provide a CFD analysis of the intake manifold, restrictor, and throttle CN192Must provide an accurate model of the engine in GT-suite

11. Engineering Specifications Spec. #ImportanceSource Specification (metric) Unit of Measure Marginal Value Ideal Value Comments/Status S11CN1 Fuel Consumption km/l6.9 8.3 Want to use ~0.7 gal for the 22km run S31CN2Power OutputHP4555 S41CN2Torqueft-lbs3135 S61CN4,15Reliabilitykm50100 Should be able to perform in all Formula SAE events and testing before major overhaul S81CN6Weightlbs7568Engine weight S91CN8Fuel TypeN/A E85 Ethanol-Gasoline Blend or 100 Octane Gasoline S121CN14Temperature°F220 200 Cooling system must keep the engine under 200 degrees in ambient temperatures up to 100 degrees

12. Sensors Necessary For Dynamometer Testing ParameterQty.Acquisition SystemRequired RangeWarning LimitUnitsMethod Throttle Position1MoTeC M4000-100 %Rotary Potentiometer Manifold Air Pressure2MoTeC M4000-110 kPaaPressure Transducer Mass Air Flow1MoTeC M4000-60 g/sCold Wire MAF Inlet Air Temperature1MoTeC M4000-100>80CThermistor Exhaust Gas Temperature4NI PCI-6034E0-950>850CK-Type Thermocouple Air Fuel Ratio1MoTeC M400.7-1.3 LambdaO2 Sensor Crank Reference Sensor1MoTeC M400 Magnetic Pickup Cam Sync Sensor1MoTeC M400 Inductive Proximity Engine Coolant Temperature1MoTeC M4000-120>90CThermistor Engine Oil Temperature1NI PCI-6034E0-150>130CThermistor Engine Oil Pressure1NI PCI-6034E0-800<140kPagPressure Transducer Barometric Pressure1MoTeC M40095-105 kPaaPressure Transducer Ambient Air Temperature1NI PCI-6034E0-50>40CThermistor Engine Crank Angle1NI PCI-6034E0-360 dATCDEncoder Cylinder Pressure1NI PCI-6034E0-5000 kPaaPiezo Pressure Transducer Fuel Pressure1NI PCI-6034E0-70 kPagPressure Transducer Fuel Inlet Flow Rate1NI PCI-6034E0-2.4 lpmTurbine Flow Meter Fuel Inlet Temperature1NI PCI-6034E0-70>60CK-Type Thermocouple Fuel Outlet Flow Rate1NI PCI-6034E0-2.4 lpmTurbine Flow Meter Injector Duty MoTeC M4000-100>90%MoTeC Parameter Spark Advance MoTeC M4000-50 dBTDCMoTeC Parameter Coolant Inlet Temperature1NI PCI-6034E0-120>90CK-Type Thermocouple Coolant Outlet Temperature1NI PCI-6034E0-120>90CK-Type Thermocouple Coolant Flow Rate1NI PCI-6034E0-70 lpmVariable Area or Turbine Knock1 YY/NKnock Tube Sensor List

13. ECM: Motec M400 Custom fuel maps for each event Controls various auxiliary devices Built-in data acquisition Engine Management System

14. System Design Schematic: Engine

15. Concept Development and Proposed Design - Engine Possible Engine Packages Weight Naturally Aspirated 250 Single Forced Induction 250 Single Naturally Aspirated 450 Single Forced Induction 450 Single Naturally Aspirated 550 V- Twin Forced Induction 550 V-Twin Naturally Aspirated 500 I2 Forced Induction 500 I2 Naturally Aspirated 600 I4 Forced Induction 600 I4 Requirements Fuel Efficient5111000 0 Reliable5010 1000 Light5111110 Practical50100 1110 Driveable41010101010 Powerful300111 011 Serviceable31010101010 Complexity311 0 0 0 Ease of calibration 311 1 1 1 Inexpensive210 0 1010 Attractive Sound 1000110011 Totals: 16-333014-1914-1116-12

16. Concept Selection and Proposed Design – Cooling System Possible Cooling System Designs Weight Oil Cooler No Oil Cooler Single Radiator Twin Radiator Fan No Fan Surge Tank No Surge Tank Electric pump Mechanical pump Requirements Light5011010000 Effective high speed5000001100 Effective low speed/off 40001100010 CG Height40101010100 Complexity30110010100 Serviceable30000000000 Cost2110 0 0 1 -214108-3173222

17. System Design Schematic: Cooling System

18. Concept Selection and Proposed Design – Fuel Choice Possible Fuel Choices Weight 93 Octane Gasoline 100 Octane Gasoline E85 Ethanol/Gasoline Requirements Power potential5011 Knock Protection4011 Energy Content4110 Corrosivity3110 Cost310 Innovative2 0 8119

19. Project Plan

21. Risk Assessment - Technical IDRisk ItemEffectCauseLSIAction to Minimize RiskOwner Technical Risks 1 Engine Dynamometer not reliable Unable to characterize engine torque Dynamometer control system not reliable 224 Be familiarized with the Dynamometer control programs. Attempt to characterize the Dynamometer and create an accurate control system in case the original is inefficient. Stanley Fofano, Phil Vars 3 Insufficient Cooling of the Engine Engine Overheats/damag e to engine Cooling system undersized or inefficient 236 Correctly analyze cooling system to maximize efficiency Evan See, Brittany Borella 4 Unable to accuractly predict airflow through the intake manifold, restrictor, and throttle Inaccurate theoretical model of engine Improper CFD analysis 224 Accurately control initial assumptions and conditions in order to create the most accurate model possible Taylor Hattori 5 Unable to accurately predict fuel consumption and power output Inefficiencies in the engine package Improper Engine Modeling 236 Verify engine model with dynamometer testing in correlation with fuel flow sensors. Jon Scanlon 8Air:Fuel Ratio too lean Damage to engine Ratio leaned out too far in order to increase fuel economy 236 Slowly change the air fuel mixture in order to realize effects before another change is made Chris Jones, Jon Scanlon

22. Risk Assessment - Management IDRisk ItemEffectCauseLSIAction to Minimize RiskOwner Project Management Risks 10 Insufficient funding Outside contracted work won't be able to be paid for Outside Contracting work is expensive 111 Use funds wisely and try to do as much in house testing as possible. When outside testing is necessary, try to take advantage of sponsorships. Brittany Borella 11 Inconsistant Team Priorities Actual Senior Design deliverables do not get met Actual engineering in the project given more priority than Senior design paperwork and deliverables 111 Project Manager(s) in charge of keeping track of all deliverables, for the class and the actual engine design, and making sure they are being taken care of by everyone on the team Evan See, Britttany Borella 12 Project not completed on time Formula team does not have a complete engine package Poor time management and planning 133 Lead engineer will make sure that sufficient time is put into all engine systems so that all components are properly tested and prepared for the final engine package Jon Scanlon 13 Parts are ordered too late Engine Dyno testing and on car testing cannot be completed on time long lead parts not identified and ordered on time 122 Long lead time parts ordered as soon as identified - early in MSD1 Jon Scanlon

23. Action Items for Detailed Design Well Documented Testing Plan BOM and 3D Model of Key Cooling System Components, Intake and Exhaust Preliminary Engine Model Wiring Diagram Baseline Engine Maps – Power Output – Fuel Economy

24. General Questions and Comments?