Internal CombustionEngine Senior Design Group

Presenters:Daniel CarpioBert SalazarMarc WorrellRick Chavez-Oropeza David PeralesErnesto Villasenor

Supervising ProfessorDr. Dunn-Rankin

The Goal

Design and build a working internal combustion engine laboratory. The engine is to be controlled by the user to run

tests and analysis for different load and engine parameter cases.

The steps in the process include the following: The engine’s electronics will be rewired to eliminate any unnecessary electrical

connections. The IC engine’s original factory computer will be bypassed with a newly

reconfigured chip. A throttle position device will be designed to the control the throttle electronically. A dynamometer will be installed to run load tests on the engine.

Time Line of Events

This table illustrates the time it will take to perform each step.

October November December January

February March April May

Engine Runningwith its own computer and wiring harness

Rewire EngineEECU and ignition system

Troubleshooting enginewiring harness and ignition system

Determine viabilitybetweenOPTO22 vs. Ourown algorithm

PD Throttlepositionlinkageemployed

Closed LoopPC Controlinitiated

IC EnginePresentation

Troubleshooting closed loopcontrol system

Attempt Lean BurnCondition with Hydrogen injection

Basic Components

Engine Stand

Engine

Wiring Harness

Basic Components (cont..)

Fuel Tank Housing

Radiator and Fan

Throttle Position Control

An adapter plate will be designed and fabricated to change the position of the throttle body on the engine.

The plate will enable the fitting of an electric motor to control the position of the throttle.

An electric circuit will be designed to control the motor, thus controlling the throttle position.

Original Throttle Plate

Throttle Position Control (cont.)

The throttle plate will attach the throttle body to the original surface on the engine.

The throttle shaft will have the exact dimensions of the original except for at the top, where a motor will be attached to the end of it.

Throttle ShaftThrottle Body

Where throttle shaft is inserted

Original Shaft

Fabricated Shaft

Throttle Position Control (cont.)

3-D Rendering of Entire Position Control

Motor

Adapter Plate

Throttle Shaft

Wiring Panel

Rewire original wire harness removing unnecessary wiring. Replace prototype wire board with a new, easier one to use. Provide a separation point in wiring to facilitate a quick

change of control devices.

Original Wiring Harness

Unused Wiring

Wiring Panel (cont.)

Wiring Board (prototype)

This board will be replaced with a new encased metal switch panel.

Original On-board Computer

Engine

Battery

Wire Connector Strip

Fuse Box

Ignition Switch

Control Chip Progress

It has been determined that OPTO-22 was inadequate for our control needs.

Controllers with required speed and flexibility have been researched. The input and output required by the engine has been identified and the

general operating scheme by which the existing factory controller functions has been determined.

The controller board search has been narrowed to four potential candidates. All of the controllers are available through Tern. (www.tern.com)

The current and voltage requirements of the inputs and outputs must now be found so that one controller may be chosen.

Dynamometer

Unit has been purchased. Delivery is expected during the fifth week of instruction.

A stand will be built for the installation of the dynamometer.

The Dynamometer will be used to provide performance and power curves for various engine test parameters.

Actual Dynamometer Unit