1. 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

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

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

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

5. 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.

6. 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

7. Top Level Design

8. Design Analysis Finite Element Analysis Computational Fluid Dynamics
Numerical Analysis

9. Final Design and Prototype

10. Final Design and Prototype

11. DAQ and Control

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

13. Verification

14. 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

15. 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

16. Questions?
Long + Adam