Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski
William Mehnert
Overview• Project Objectives• Project Goals• Project Background• Design Approach• Conceptual Design• Ignition Timing• Fuel Control• Closed Loop Control• Deliverables• Equipment needed• Budget• Nugget Chart• Project Management• 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
Project Goals
• Design a kit for the public to use without major modification to the engine
• Understand the benefits of alternative fuels and the behavior of the engine using Ethanol-gasoline blends
• Understand the effects of the different blends up to E85
Project Background
• Ethanol vs. gasoline– Octane number– Brake Specific Fuel
Consumption– Heating Value
• Production and Availability
• Environment Protection Association standards
• Existing products
Design Approach
• Engine Option– 1 cylinder Briggs
and Stratton
Engine Configuration
3.5 HP air cooled, 4 stroke, horizontal engine
Engine Displacement 9.02 cu. In.
Max speed 4000 rpm
Bore x Stroke 2.56 x 1.75 in
Fuel Delivery System Float type carburetor
Design Approach (contd)
• Engine Options– 1998 Suzuki
GSXR 750cc– Open loop ECM
Engine Configuration Inline Four, 4-Stroke,
DOHC
Engine Displacement 749 cc
Compression Ratio 11.8:1
Valves Per Cylinder 4
Bore x Stroke 72 x 46 mm
Measured Peak Horsepower 135 bhp @ 12,500 rpm
Measured Peak Torque
62 lbs. - ft. @ 10,00 rpm
Combustion Chamber Volume 17.3 cc
Fuel Delivery System Fuel Injection
Ignition System Digital Electronic
Design Approach (contd)
• Engine Option– 2001 Suzuki
GSXR 600cc
– Closed loop ECM
Engine Configuration Inline Four, 4-Stroke,
DOHC
Engine Displacement 599 cc
Compression Ratio 12.2:1
Valves Per Cylinder 4
Bore x Stroke 67 x 42.5 mm
Measured Peak Horsepower 115 bhp @ 12,500 rpm
Measured Peak Torque
69 lbs. - ft. @ 10,000 rpm
Fuel Delivery System Fuel Injection
Ignition System Digital Electronic
Design Approach (contd)
• Ignition timing Control– ECM: control spark timing and fuel– Encoder or crank angle sensor: measure
crank angle to adjust timing
• Control system design– Flex Fuel Sensor: Ethanol-Gasoline blend– Exhaust Gas Temperature: Optimize
timing
– O2 content sensor: Detect complete burn
Why concentrate on Ignition Timing?
• Directly affects combustion temperature
• Combustion temperature affects emissions
• Main cause of engine knock or pre-detonation
• Effects power output• Must be adjustable to compensate for
different blends of Ethanol-Gasoline
Ignition Timing
• Measured as degrees before Top Dead Center
• Must leave time for flame propagation
• Early ignition creates high pressures and engine knock leading to failure
• Late ignition leads to poor power output
Fuel Control
• Directly affects Horsepower (heating value of fuel)
• Adjust Air/Fuel ratios for proper combustion/emissions
http://www.rceng.com/technical.aspx?UserID=230225&SessionID=SiEH2zhKsmej8veflxBT
Feedback
• Oxygen Sensor– Adjust fuel consumption
• Flex Fuel Sensor– Determine ethanol mixture– Winter and summer blends, etc
• Exhaust Gas Temperature– Chamber temperatures lead to detonation– Risk of melting internal components
• Emissions– High temperature leads to high NOx– Low temperature leads to high HC
Closed Loop system
• FFS used for primary ignition table
• Sensors used for trim values
Deliverables
• Emissions readings– CO– NOx– HC
• Torque (HP Calculated)
• Fuel Consumption
• Sensitivity Analysis
Equipment Needed
• Engine – Fuel Injected with Electronic Timing
• ECM – Megasquirt or Equivalent
• Sensors – FFS, EGT, O2
• Dynamometer (Time) – Outsourced
Budget
Area ofCommodity
Part Name/Labor Quantity Price/Part and Labor Total Cost
Engine Engine 1 $1,500.00 $1,500.00
Engine Injectors 4 $50.00 $200.00
Control system ECM 1 $700.00 $700.00
Sensor Flex Fuel Sensor 1 $600.00 $600.00
Sensor Wideband 1 $200.00 $200.00
Sensor EGT 1 $150.00 $150.00
Testing Dynamometer 6h $80.00/h $480.00
Shipping andhandling Shipping 5 $30.00 $150.00
Total $3,980.00
Nugget Chart
Project Management
• Task Management– Research – Product Development
• Refinement• Architecture
– Engineering, tuning and testing– Deliverables
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
Thank you
• Any Questions?
Sensitivity Analysis
• Timing vs. ALL– Use conservative Air/Fuel Ratios and
measure against all Parameters for a specific RPM
• Fuel vs. ALL– Use steady timing and measure all
parameters for a specific RPM
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• 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