Michigan Tech Clean Snowmobile Michigan Tech Clean Snowmobile Challenge Enterprise Challenge Enterprise –– Results SummaryResults Summary

Matt PrusakNick Dahlheimer

Advisor: Dr. Bernhard Bettig

OutlineOutline

• 2005 Clean Snowmobile Design• SAE Clean Snowmobile Challenge• Summary of Results• Lessons Learned• Plans for Next Year and Beyond

2005 Clean Snowmobile Design2005 Clean Snowmobile Design

• Engine Choice/Modifications• Chassis Selection/Modification• Power Adaptation Strategy• Drive System Features• Noise Reduction

Engine ChoiceEngine Choice

• Honda CBR954RR– 4-Stroke– 4 cylinder– 4 valves per cylinder– Electronic Fuel

Injection– Naturally Aspirated

Engine ModificationsEngine Modifications

• Under-Seat Exhaust Configuration Optimized via Lotus Engine Simulation Software

• 3-way Metal substrate catalytic exhaust treatment

• Fuel Injection Optimization

Chassis Selection/ModificationChassis Selection/Modification

• 2004 Polaris Pro-X Chassis

• Over-the Engine Steering for Enhanced Ergonomics and Reduced Complexity

Power Adaptation StrategyPower Adaptation Strategy

• Balanced Output Shaft Adapted to Magneto Side of Engine Crankshaft

• CNC Machined Engine Side Cover to Support Output Shaft

Power Adaptation Strategy, cont.Power Adaptation Strategy, cont.

• Finite Element Analysis, Fatigue Analysis on both Output Shaft and Cover

• Safety Factors well within Acceptable Margins

Drive System FeaturesDrive System Features

• Micro Belmont primary clutch

• Team Industries rapid reaction roller secondary clutch

• FAST gearbox• Shaft support arm

– FE Analysis

Noise Reduction Noise Reduction –– Muffler DesignMuffler Design• Frequency analysis

completed• Peak frequencies

identified• Muffler tuned to

eliminate peak frequencies

Noise Reduction Noise Reduction –– Other AreasOther Areas

• Various tracks tested on simulation stand

• Sound absorption foam used to reduce under hood noise

• Motor mount bushings integrated to reduce vibration

Preliminary ResultsPreliminary Results

• Clean– Greater than 95% reduction in HC and

CO2– Greater than 78% reduction in NOx– Increased Fuel Economy, 14.5 MPG– Reduction in burned oil

• Quiet– Significant reduction in exhaust noise– Suspension and track noise reduction

Additional Benefits Additional Benefits • Affordable

– $1314 additional technology per CSC TICA Form• Reduced Maintenance

– Seasonal Oil Change, Reduced Spark Plug Fouling– Lower Cost of Maintenance

• Easy Tunability– Simple clutch tuning transforms a touring sled into a high

performance machine in minutes for minimal cost• Increased Durability

– Drive System, Four-Stroke Reliability

SAE Clean Snowmobile ChallengeSAE Clean Snowmobile Challenge

The Clean Snowmobile Challenge is one of SAE's collegiate design competitions that challenges engineering students to reengineer an existing snowmobile for improved emissions and noise while maintaining or improving the performance characteristics of the original snowmobile. The modified snowmobiles are also expected to be cost-effective.

2005 Competition Results2005 Competition Results• 13 competitors from across the snow belt• Achievements

– 1st place, static display– 2nd place, overall emissions

• Cleaner than several engines with less than half of our power output

• Mishaps– Did not pass initial endurance event

due to excessive under-seat heat, boiling fuel inside gas tank (insufficient test time)

– Did not pass noise due to excessive noise emitted by FAST gearbox

-Design Paper – 3rd

-Static Display – 1st

-Cost – 6th

-Fuel Economy – N/A-Oral Presentation – 6th

-Noise – N/A -Rider Comfort – 5th

-Acceleration – 4th

-Emissions – 2nd

-Cold Start – Pass-Handling – 11th, 4th

-OVERALL: 6th place

Lessons LearnedLessons Learned

• Time to test before competition is critical– Improve utilization of timeline

• One-year design cycle is extremely difficult– Implement two-year design cycle

• Manufacture any and all parts possible ourselves– Reduce dependency on outsourcing, reduce

lead times, improve quality

Plans for Next Year and BeyondPlans for Next Year and Beyond• Refine 954 sled for 2006 competition

– New gearbox, helical gears to reduce noise, designed and manufactured by MTU students

– Redesigned exhaust configuration to reduce heat under tank– Custom drivetrain components to reduce engine operating

speed during cruising (reduces noise, emissions, fuel consumption)

– Increase testing time***– Reduce system weight

• While refining 954, begin design cycle on new platform for 2007 competition– Lightweight race-specific chassis– Compact, lightweight parallel-twin turbocharged four stroke

THANK YOU!THANK YOU!

Questions?Questions?