Engine Team Design Review 3

FSAE Engine Team

Bryce Ito, Logan Farnsworth, Brian Hoggard, Erik Casper, Jonah Petit, Nate Rutter

Team Members (from left)

INTRODUCTION

ASUU Club, drivetrain (gearing and differential)

Throttle body, intake plenum and runners, motor rebuild

Slipper clutch integration, clutch plate release mechanism

Team leader, Engine Control Unit, wire harness, sensors

Gear shifting actuation, button shifter

BOM, exhaust manifold, cooling system, fuel

Bryce

Brian

Erik

Logan

Nate

Jonah

OVERVIEW

• Project Overview• Project Schedule & Expectations• Critical Metrics & Testing Plan• Current Achievements• Technical Discussion• Look ahead to Design Day• Summary• Questions

PROJECT OVERVIEW

Engine• Intake & Throttle Body• Ignition System• ECU & Tuning• Engine Internals• Exhaust System

Drivetrain• Slipper Clutch• Shifting System

Objective: To design, engineer, and build a powertrain system that complements the design aspects of the chassis and suspension and maximizes power output.

SCHEDULE

GOALS FOR REVIEW 3 STATUS

Powder coat drivetrain Finished, then removed

Assemble the drivetrain

Waiting for bearings, Need to fix tolerances

Mate the drivetrain to engine Mostly done

Install the cooling system Dependent on the completion of the chassis

Installation of electrical system

Dependent on the completion of the chassis

Complete the shifting system

Finished Design, Still being manufactured

STATUS OF EXPECTATIONS

CRITICAL METRICSMETRIC 2006 CAR 2011 CAR

Max Horsepower 80 26 ?RPM for Max Horsepower 12000 3000 ?Max Torque (Nm) 58 15 ?RPM for Max Torque 8500 3000 ?Powerband Torque (Nm) 50 ?Powerband Min (RPM) 5000 ?Powerband Max (RPM) 11000 ?Acceleration Event: Final Speed (MPH) 70 ?

RPM 8,500TORQUE (Nm) 58.0

RPM 11,000

HP 80

Analyze the results from the Dyno

CURRENT ACHIEVEMENTSMotor and Drivetrain Assembly

Throttle Body

CURRENT ACHIEVEMENTS

Dynamometer Establish a matching gear set

TECHNICAL DISCUSSION

• Determine the final drive gear ratio for the acceleration event– Target Speed: 70 mph– Target RPM: 11,000– Outer Diameter of Tire: 20.37 in

Source: Car Craft, March 2010, p 47

TECHNICAL DISCUSSION(Cont.) Gearbox Assembly

Output gear

Output pinion

Input gearInput pinion

Gear ratio = 4.05:1

TECHNICAL DISCUSSION(Cont.)

ITEM SPECIFICATIONPrimary Reduction 1.863

Gear Ratio 1st 2.929

Gear Ratio 2nd 2.063

Gear Ratio 3rd 1.647

Gear Ratio 4th 1.368

Gear Ratio 5th 1.200

Gear Ratio 6th 1.087

Final reduction 2.867

Gearbox Assembly

Source: 1995 – 97 Honda CBR600F3 Service Manual, p. 1-5

Number of TeethInput Pinion Gear 24

Input Gear 37

Output Pinion 19

Output Gear 50

Input Module 2.5Output Module 3

Engine Manufacturer Specifications

TECHNICAL DISCUSSION (Cont.)Problems Encountered

Tolerances & Bearings

Integrate an axle seal

LOOK AHEAD TO DESIGN DAY

• Critical Metrics for 2011 Formula Car • Engine/Drivetrain Assembled

o Achieve the critical metricsoEngine and Drivetrain Installed oFix the bearing tolerancesoInstall Gaskets

• Install all systems that interface with the chassis o Cooling Systemo Electrical Systemo Shifting SystemoExhaust System

SUMMARY

• Project Overview• Project Schedule & Expectations• Critical Metrics & Testing Plan• Current Achievements• Technical Discussion• Looking ahead to Design Day

Questions???