engine team design review 3
DESCRIPTION
Design Presentation given on 3/18/11 at Design Review (I gave the first half of the presentation)TRANSCRIPT
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???