Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski

William Mehnert

Overview• Project Objectives• Phase Overview

– Phase 1– Phase 2

• Bill of Materials• Component Overview• Software Flow Chart• Program Logic• Test Bed• Nugget Chart• Conclusion

Project Objective

• Convert a gasoline engine to operate on E85 without sacrificing fuel consumption, increasing performance and reducing emissions

• Provide a control system unit to manage the engine

Phase 1 Overview

• Evaluation of design approaches (different engines)

• Research of existing products• Ignition timing is most important aspect of

performance

Phase 2 Overview

• Areas of Technical Analysis– Ignition Timing– Explosion Limits– Emissions– Power/Torque

Bill of Materials

• Total = $3,279.50

Component From Price Function

Megasquirt (ECM) DIYAutotune.com $436 Engine Control

Exhaust temperature lethaldiesel.com $78 Timing Control

Oxygen Sensor Summitracing.com $200 Air/Fuel Ratio Control

Flex Fuel Sensor Gmpartsdirect.com $363 Fuel Composition

Fuel Injector Summitracing.com $250 Fuel adjustments

Engine E-bay or other used parts market place

$1200 Testing

Dynamometer Local performance shop $80/test Testing

Emissions Local testing center $80/test Testing

E85 Fuel Closest E85 Station $2.75/Gallon Fuel

Misc Sensors and Circuits

Mouser.com or Digikey.com $165 Control Circuits

*Prices do not include taxes and shipping fees.

Component Overview

• Megasquirt – Standalone ECM– Allows for full programmability and control

of all engine parameters– Allows for development of control

algorithms

Component Overview• EGT Sensor

– Detects exhaust gas temperature (Chamber temperature)

Oxygen Sensor, wideband

-Detects air/fuel ratio

Component Overview• Flex Fuel Sensor

– Detects ethanol content in the fuel

Software Flow Chart

ECM

Exhaust Gases

FFS Fuel

Injectors Ignition O2 EGT

Program Logic

• Read FFS to determine ethanol content– Trim fuel table and timing table to compensate

• Read Oxygen Sensor– Trim fuel values to bring values back to

stoichiometric or towards desired target• Read EGT sensor

– Trim timing values to adjust EGT temperatures to acceptable range and reduce emissions.

• Check throttle position– Adjust timing and fuel lookup tables to create

power as demanded.

Test Bed

• Track of dyno – 24”-96”– Track of current SAE car - ~62”– Used to tune vehicle for power, torque, and

emissions

• 5 Gas emissions testing

Nugget Chart

Conclusion

• With ignition timing, we will control the combustion in the cylinder chamber

• We will provide a kit that will enable someone to run on E85/gasoline blend

• The testing will consist of two identical runs; one with gasoline and one with E85

• The results will be directly compared to determine to the differences in the theoretical values vs. the actual values.

Thank you

• Any Questions?

Reference• www.change2E85.com• www.megasquirt.info• www.flextek.com• www.e85fuel.com• www.eere.energy.gov• www.diablosport.com• www.e85vehicles.com• www.e85prices.com• www.aa1car.com• http://www.eng-tips.com/viewthread.cfm?qid=33615• http://www.engineeringtoolbox.com/explosive-concentration-limits-d_423.html• http://www.allpar.com/fix/EPAMethods.html• http://www.techedge.com.au/vehicle/wbo2/wblambda.htm• Effect of Advanced injection timing on emission characteristics of diesel

engine running on natural gas• Effect of Ethanol-gasoline blends on engine performance and exhaust

emissions in different compression ratio• The effects of ethanol-unleaded gasoline blends and ignition timing on

engine performance and exhaust emissions

Chemical Equilibrium

• Gasoline – C8H18+12.5(O2+3.76N2)

CO2+3H2O+12.5(3.76N2)

• Ethanol– C2H5OH+3(O2+3.76N2)

2CO2+3H2O+3(3.76N2)

Formulas Used