FSAE Turbocharger - Kevin Ferraro

Report
Formula SAE Turbocharger:
Problem Statement: Successfully implement a
turbocharger system on the current WR450 single
cylinder engine.
Constraints:
1.
2.
3.
4.
5.
6.
Engine compartment restrictions from chassis
Minimize system weight
Cost (With or without sponsorship)
Maintain controlled temperature
Spares for all parts must be available
FSAE rules and regulations
Object
Honeywell Turbo
University of Wisconsin FSAE (2010)
Yamaha Phazer Turbo
Origin
Honeywell/Garrett
IHI wastegate controlled (RHF3)
Mitsubishi brand turbo
Cost
$643
-
$5,499 (full kit for snowmobile)
GT12 Family
Smallest produced by Garrett
50-130 hp range
Recommended 400cc to 1200cc engine
size
Journal Bearing system
Oil & Water Cooling
Japanese Manufacturer
Running KTM 525 XC
Compression Ratio - 10.4:1
Kit for Yamaha Phazer
4 stroke 500cc engine
Produces 136 hp (unrestricted)
E-85 ethanol
at 12 psi
max power design at 7600 RPM
max torque design at 6000 RPM
min RPM for 80% max torque 5000
RPM
3.5 Bar fuel pressure
1400cc intake plenum volume
Max spark advance: 29 deg BTDC at
9000 RPM WOT
small, fast reacting turbo
Information
Inducer: 29 mm
Exducer: 41 mm
Trim: 50
A/R: 0.33
Turbine Wheel: 35.5 mm
Turbo in series with engine dry sump
Trim: 72
A/R: 0.43
Internally Wastegated
No intercooler
Wiseco forged piston
Most efficient between 0.7-1 Bar boost
Difficulty
Unit of
Measure
Ideal
Value
Source
Function
Specification (metric)
CN1
Engine
Peak Power Output
S2
CN1, 2
Intake
Mass Air Flow
g/s
>=50
S3
CN1, 2
Intake
Plenum Volume
cc
>=1000
S4
CN3
Sensors
Sensor Voltage
V
5
S5
CN1, 5, 15
Intercooler
Air Temperature Reduction
Deg F
>=20
S6
CN1, 2, 5
Intake
Manifold Air Temperature
Deg F
<=100
S7
CN1, 7, 9
Turbo
Turbine Shaft RPM
rpm
S8
CN1, 7, 9
Turbo
Intake Manifold Pressure
psi
~100,00
0
>=20
S9
CN7, 9, 13
Turbo
Peak Compression by RPM (specified)
rpm
<=6000
S10
CN2, 3
Sensors
Air Fuel Ratio Range
S11
CN1, 3
Sensors
Manifold Air Pressure Range
psi
0-30
S12
CN3,4,13,
17
Turbo
Pressure to Actuate Wastegate
psi
>=20
S13
CN1,11,17
Exhaust
Flow Rate
g/s
>=100
S14
CN8
Exhaust
Noise Level
dBa
<110
S15
CN3,5,7,16
Turbo
Max Temperature of Turbo
Deg F
<800
S16
CN7,11,18
System
Overall Maximum Weight Increase
lbs
<=15
S17
CN1,3,4,6
Engine
Compression Ratio
S18
CN1,13
Engine
Max Power Design RPM
rpm
~9000
S19
CN1,13
Engine
Max Torque Design RPM
rpm
~7000
S20
CN1,3,13
Engine
Max Spark Advance
deg
40-45
S21
CN4,16,18
Funding
Cost to Formula Team
$$$
<100
S1
Hp and ft- >= 60hp
lbs
45 ft-lbs
Comments/Status
General increase overall can also
compensate
Maximize for restrictor
May not be needed
Depending on turbo chosen
12.6<x<
17.6
~10:1
Based on FSAE regulation
Max achievable without engine knock
Funding/Sponsorship will be required
Customer Needs
X
X
X
X
Cost to Formula Team
X
X
X
X
X
X
X
X
X
X
X
Max Spark Advance
Max Torque Design RPM
Max Power Design RPM
X
X
X
Compression Ratio
Overall Maximum Weight Increase
Max Temperature of Turbo
Noise Level
Flow Rate (Exhaust)
X
X
X
Pressure to Actuate Wastegate
X
Manifold Air Pressure Range
X
Air Fuel Ratio Range
Peak Compression by RPM (specified)
X
Intake Manifold Pressure
X
Turbine Shaft RPM
Sensor Voltage
Plenum Volume (Intake)
X
Manifold Air Temperature
X
Air Temperature Reduction (intercooler)
Overall HP & Torque Gains
Optimized ECU Map
Consistent Performance
Necessary Engine Internals
Adequate System Cooling
Sufficient Dyno Testing
Optimized Turbo Size for Application
Meet FSAE Noise Regulations
Quick Throttle Response
Easy to Access in Car
Compact Design in Car
Fit Within Constraints of Chasssis
Easy to Drive
Design Drivetrain Components for Power Increase
Design for Intercooler Location
Readily Available Replacement Parts
Simple interface with Current Engine
Maximize Use of Composite Materials
Mass Air Flow (Intake)
Peak Power Output
Specifications
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Staffing:
Qty
Description
Lead (ME)
1
Responsible for system integration with chassis, engine, drivetrain, and
electrical components. Also responsible for management duties, and
engine calibration
Thermal (ME)
1
Responsible for heat management of the system. Will require work
with FEA, Pro Engineer, Heat Transfer, and System Dynamics
2
Responsible for fluid flow analysis through each individual subcomponent of the system. Will require work with CFD, Pro Engineer,
Fluid Mechanics, System Dynamics, IC Engines, and FEA
1
Responsible for structural integrity of the system. Will require analysis
of vibration and stresses through use of FEA, Pro Engineer, Statics, and
System Dynamics.
Fluids (ME)
Structures
(ME)
*Formula SAE experience preferred for all positions

Main concern with scope is time constraints
◦ Project may be used as development for future cars rather
than implementing on F21
◦ Lessons learned can be advantageous in design competition
◦ Cost may be an issue without appropriate sponsorships

Specifications are reasonable, some flexible
◦ Overall system gains must justify weight and cost increase
◦ Expected to set ambitious goals for top ranking car

Project staffing is realistic
◦ Communication between team members will be crucial to
the quality of the project

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