KGCOE MSD Technical Review

P12221: Lightweight Fuel Efficient Engine Package

Meeting Purpose:

1.Overview of the Project

2.Confirm Engineering Specifications and Customer Needs

3.Review Concepts

4.Propose a design approach and confirm its functionality

5.Cross disciplinary review: generate further ideas

Materials Reviewed:

1.Project Description

2.Work Breakdown Structure

3.Customer Needs

4.Customer Specifications

5.Current System Design Schematic

6.Concept Development and Proposed Design – Base Engine

7.Concept Development and Proposed Design – Something else

8.Project Plan

9.Risk Assessment

Meeting Date:

Meeting Location:

Meeting time (indicate start and stop time for entire review):

Timeline:

Meeting Timeline
Start time / Topic of Review / Required Attendees
Project # / Project Name / Project Track / Project Family
P12221 / Lightweight Fuel Efficient Engine Package / Vehicle Systems and Technologies
Start Term / Team Guide / Project Sponsor / Doc. Revision
20111 / Dr. Nye / RIT Formula SAE Team

KGCOE MSDPage 1 of 12Technical Review

KGCOE MSD Technical Review

P12221: Lightweight Fuel Efficient Engine Package

Project Description

Project Background:

●RIT Formula SAE team needs a more fuel efficient engine package

●Past projects

●Related Projects

Problem Statement:

Develop a more fuel efficient and powerful single cylinder engine package to be used by the RIT Formula SAE 2012 car.

Objectives/Scope:

1.Ability to produce over 60 HP

2.Smooth, drivable power delivery

3.Intuitive driver controls

4.Extremely reliable

5.Able to operate at ambient temperatures up to 100F under racing conditions

6.Separate maps for high power and optimum fuel efficiency

7.Capable of using 60% of fuel of previous engine package over similar run

8.Well understood and documented development process

Deliverables:

○Engine Package

○Cooling System

○Engine Model and CFD Anaylsis

○Wiring Diagram

○Engine Maps for Power Output and Fuel Economy

○Documented Deliverables for SD I & II

Expected Project Benefits:

○The RIT Formula SAE team will have a reliable and efficient engine package to power their car, therefore earning them more points at competitions.

Core Team Members:

○Evan See

○John Scanlon

○Chris Jones

○Taylor Hattori

○Stanley Fofano

○Brittany Borella

Strategy & Approach

Assumptions & Constraints:

1.RIT Formula Race Team previously decided on a single cylinder engine - 2010 Yamaha WR450F

2.Must comply with all Formula SAE Rules, including, but not limited to:

a.Use provided race fuel: 93 or 100 octane gasoline, or E85 Ethanol

b.Spark ignition

c.Four stroke

3.Limited to Formula Team’s Budget as well as the amount provided by Senior Design

Issues & Risks:

  1. Increased Efficiency will reduce power output
  2. Sponsorship by companies may result in longer lead times than if we were paying customers
  3. Cooling System has proved to be difficult to efficiently design
  4. A Possibility that the Engine Dynamometer will not reliable under load
  5. Possibly Inaccuracies in the Engine model and CFD analysis

KGCOE MSDPage 1 of 12Technical Review

KGCOE MSD Technical Review

P12221: Lightweight Fuel Efficient Engine Package

KGCOE MSDPage 1 of 12Technical Review

KGCOE MSD Technical Review

P12221: Lightweight Fuel Efficient Engine Package

Customer Needs
Revision #: A
Customer Need # / Importance / Description / Comments/Status
Engine
CN1 / 1 / The engine must reduce fuel consumption when compared to the previous engine package
CN2 / 1 / The engine must provide sufficient power output and acceleration
CN3 / 1 / The engine must be able to be effectively integrated into rest of vehicle
CN4 / 1 / The engine package must be reliable continuously under strenuous conditions
CN5 / 2 / The engine must provide smooth power delivery
CN6 / 2 / The engine package must be lightweight
CN7 / 2 / The engine package must be small
CN8 / 1 / The engine must operate using one of the specified fuels dictated by Formula SAE
CN9 / 1 / The engine package must comply with all Formula SAE Rules
CN10 / 1 / The engine must operate under safe conditions
Control System
CN11 / 2 / The control system must provide accurate fuel delivery and measurement
CN12 / 3 / The control system should assist in traction control
CN13 / 2 / Driver controls must be intuitive
Cooling System
CN14 / 1 / The cooling system must be able to allow the engine to operate in high ambient temperatures under race conditions
CN15 / 1 / The cooling system must be reliable under strenuous conditions
CN16 / 2 / The cooling system must be lightweight
Documentation and Testing
CN17 / 1 / Documented theoretical test plan and anticipated results
CN18 / 1 / Must provide a CFD analysis of the intake manifold, restrictor, and throttle
CN19 / 2 / Must provide an accurate model of the engine in GT-suite
CN20 / 2 / Create an off car test plan using the engine dyno
CN21 / 2 / Create an on car test plan
CN22 / 1 / Collect empirical data for fuel flow, coolant flow, heat transfer, power output
CN23 / 3 / Develop a wiring diagram
CN24 / 2 / Create engine map for highest power output
CN25 / 2 / Create engine map for optimized fuel economy
Cust. Need #: enables cross-referencing (traceability) with specifications
Importance: scale 1=must have, 2=nice to have, 3=preference only

KGCOE MSDPage 1 of 12Technical Review

KGCOE MSD Technical Review

P12221: Lightweight Fuel Efficient Engine Package

Engineering Specifications
Revision #:A
Spec. # / Importance / Source / Specification (metric) / Unit of Measure / Marginal Value / Ideal Value / Comments/Status
S1 / 1 / CN1 / Fuel Consumption / km/gal / 36.67 / Want to use 0.6 gal for the 22km run
S2 / 1 / CN1 / Fuel Consumption / % / -0.6 / 60% reduction in fuel consumption over previous design
S3 / 1 / CN2 / Power Output / HP / 48 / 60
S4 / 1 / CN2 / Torque / ft-lbs / 31 / 35
S5 / 1 / CN3,7 / Volume / ft^3 / 2.3 / 1.8 / Engine package must fit in a smaller volume than the previous engine package
S6 / 1 / CN4,15 / Reliability / km / 30 / 50 / Must be able to perform in all Formula SAE events without failure
S7 / 2 / CN5,13 / Driver Feedback / N/A / Throttle response and torque, paddle shifting
S8 / 1 / CN6 / Weight / lbs / 125 / 68
S9 / 1 / CN8 / Fuel Type / N/A / E85 Ethanol-Gasoline Blend or 100 Octane Gasoline
S10 / 2 / CN10 / Number of Moving Parts / # / Simplicity in engine design
S11 / 2 / CN10,11 / Air:Fuel Ratio / Ratio / 14.7
S12 / 1 / CN14 / Temperature / °F / 190 / Cooling system must keep the engine under 190 degrees in ambient temperatures up to 100 degrees
Spec. #: enables cross-referencing (traceability) and allows mapping to lower level specs within separate documents
Source: Customer need #, regulatory standard (eg. EN 60601), and/or "implied" (must exist but doesn't have an associated customer need), constraint
Possible Engine Packages
Weight / Naturally Aspirated 250 Single / Forced Induction 250 Single / Naturally Aspirated 450 Single / Forced Induction 450 Single / Naturally Aspirated 550 V-Twin / Forced Induction 550 V-Twin / Naturally Aspirated 500 I2 / Forced Induction 500 I2 / Naturally Aspirated 600 I4 / Forced Induction 600 I4
Requirements / Fuel Efficient / 5 / 1 / 1 / 1 / 0 / 0 / -1 / 0 / -1 / 0 / -1
Reliable / 5 / 0 / -1 / 1 / 0 / -1 / -1 / 1 / 0 / 0 / 0
Light / 5 / 1 / 1 / 1 / 1 / 1 / 0 / -1 / -1 / -1 / -1
Practical / 5 / -1 / 0 / 1 / 0 / 0 / -1 / 1 / 1 / 1 / 0
Driveable / 4 / 1 / 0 / 1 / 0 / 1 / 0 / 1 / 0 / 1 / 0
Powerful / 3 / -1 / 0 / 0 / 1 / 1 / 1 / -1 / 0 / 1 / 1
Serviceable / 3 / 1 / 0 / 1 / 0 / 1 / 0 / 1 / 0 / 1 / 0
Complexity / 3 / 1 / -1 / 1 / -1 / 0 / -1 / 0 / -1 / 0 / -1
Ease of calibration / 3 / 1 / -1 / 1 / -1 / 1 / -1 / 1 / -1 / 1 / -1
Inexpensive / 2 / 1 / -1 / 0 / -1 / 0 / -1 / 1 / 0 / 1 / 0
Attractive Sound / 1 / -1 / 0 / 0 / 0 / 1 / 1 / 0 / 0 / 1 / 1
16 / -3 / 33 / 0 / 14 / -19 / 14 / -11 / 16 / -12
Possible Cooling System Designs
Weight / Oil Cooler / No Oil Cooler / Single Radiator / Twin Radiator / Fan / No Fan / Surge Tank / No Surge Tank / Electric pump / Mechanical pump
Requirements / Light / 5 / 0 / 1 / 1 / 0 / -1 / 1 / 0 / 0 / 0 / 0
Effective high speed / 5 / 0 / 0 / 0 / 0 / 0 / 1 / 1 / -1 / 0 / 0
Effective low speed/off / 4 / 0 / 0 / 0 / 1 / 1 / 0 / 0 / 0 / 1 / 0
CG Height / 4 / 0 / 1 / 0 / 1 / 0 / 1 / 0 / 1 / 0 / 0
Complexity / 3 / 0 / 1 / 1 / 0 / 0 / 1 / 0 / 1 / 0 / 0
Serviceable / 3 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0 / 0
Cost / 2 / -1 / 1 / 1 / 0 / -1 / 0 / -1 / 0 / -1 / 1
-2 / 14 / 10 / 8 / -3 / 17 / 3 / 2 / 2 / 2
Possible Fuel Choices
Weight / 93 Octane Gasoline / 100 Octane Gasoline / E85 Ethanol/Gasoline
Requirements / Power potential / 5 / 0 / 1 / 1
Knock Protection / 4 / 0 / 1 / 1
Energy Content / 4 / 1 / 1 / 0
Corrosivity / 3 / 1 / 1 / 0
Cost / 3 / 1 / -1 / 0
Innovative / 2 / -1 / -1 / 0
8 / 11 / 9

Engine Diagram


Risk Assessment

ID / Risk Item / Effect / Cause / L / S / I / Action to Minimize Risk / Owner
Technical Risks
1 / Engine Dynamometer not reliable / Unable to characterize engine torque / Dynamometer control system not reliable / 2 / 2 / 4 / Load Dynamometer with engine to describe how well it behaves with the load. Be familiarized with the Dynamometer control programs. Attempt to characterize the Dynamometer and create an accurate control system in case the original is inefficient. / Stanley Fofano, Phil Vars
2 / Insufficient Amount of Horsepower provided / Team will lose events having to do with speed and acceleration / Single Cylinder Engine Underpowered or improperly tuned / 1 / 3 / 3 / Sufficient on and off car testing to determine if tuning meets specifications and develop a reaction plan early on in the project to determine appropriate actions if specifications are not met / Chris Jones
3 / Insufficient Cooling of the Engine / Engine Overheats/damage to engine / Cooling system undersized or inefficient / 2 / 3 / 6 / Correctly analyze cooling system to maximize efficiency / Evan See, Brittany Borella
4 / Unable to accurately predict airflow through the intake manifold, restrictor, and throttle / Inaccurate theoretical model of engine / Improper CFD analysis / 2 / 2 / 4 / Accurately control initial assumptions and conditions in order to create the most accurate model possible / Taylor Hattori
5 / Unable to accurately predict fuel consumption and power output / Inefficiencies in the engine package / Improper Engine Modeling / 2 / 3 / 6 / Verify engine model with dynamometer testing in correlation with fuel flow sensors. / Jon Scanlon
6 / All parameters not accurately tested / Inaccurate assumptions used in final tuning / Test plan insufficient / 1 / 2 / 2 / Create Test Plan to include testing of important assumptions and add to it when more parameters are identified as necessary / Chris Jones, Jon Scanlon
7 / Insufficient or inaccurate empirical data collected from the engine / Unable to accurately analyze and adjust fuel flow, coolant flow, heat transfer, and power output / Sensors installed incorrectly, installed in the incorrect locations, or are undersized/underspec'ed / 1 / 2 / 2 / Appropriate Sensors Spec'ed out properly / Chris Jones, Stanley Fofano
8 / Air:Fuel Ratio too lean / Damage to engine / Ratio leaned out too far in order to increase fuel economy / 2 / 3 / 6 / Slowly change the air fuel mixture in order to realize effects before another change is made / Chris Jones, Jon Scanlon
9 / Engine/Cooling system too heavy / Decreased power to weight ratio / Poor design of engine and cooling system / 1 / 3 / 3 / Correctly analyze cooling system to maximize efficiency so that its size can be reduced as much as possible / Evan See, Brittany Borella, Chris Jones
Project Management Risks
10 / Insufficient funding / Outside contracted work won't be able to be paid for / Outside Contracting work is expensive / 1 / 1 / 1 / Use funds wisely and try to do as much in house testing as possible. When outside testing is necessary, try to take advantage of sponsorships. / Brittany Borella
11 / Inconsistent Team Priorities / Actual Senior Design deliverables do not get met / Actual engineering in the project given more priority than Senior design paperwork and deliverables / 1 / 1 / 1 / Project Manager(s) in charge of keeping track of all deliverables, for the class and the actual engine design, and making sure they are being taken care of by everyone on the team / Evan See, Britttany Borella
12 / Project not completed on time / Formula team does not have a complete engine package / Poor time management and planning / 1 / 3 / 3 / Lead engineer will make sure that sufficient time is put into all engine systems so that all components are properly tested and prepared for the final engine package / Jon Scanlon
13 / Parts are ordered too late / Engine Dyno testing and on car testing cannot be completed on time / long lead parts not identified and ordered on time / 1 / 2 / 2 / Long lead time parts ordered as soon as identified - early in MSD1 / Jon Scanlon

KGCOE MSDPage 1 of 12Technical Review