group 9a: jerry dutreuil joshua guerra matt grywalski
DESCRIPTION
E85 Conversion Kit. 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 - PowerPoint PPT PresentationTRANSCRIPT
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Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski
William Mehnert
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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
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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
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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
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Project Background
• Ethanol vs. gasoline– Octane number– Brake Specific Fuel
Consumption– Heating Value
• Production and Availability
• Environment Protection Association standards
• Existing products
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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
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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
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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
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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
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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
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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
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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
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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
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Closed Loop system
• FFS used for primary ignition table
• Sensors used for trim values
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Deliverables
• Emissions readings– CO– NOx– HC
• Torque (HP Calculated)
• Fuel Consumption
• Sensitivity Analysis
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Equipment Needed
• Engine – Fuel Injected with Electronic Timing
• ECM – Megasquirt or Equivalent
• Sensors – FFS, EGT, O2
• Dynamometer (Time) – Outsourced
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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
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Nugget Chart
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Project Management
• Task Management– Research – Product Development
• Refinement• Architecture
– Engineering, tuning and testing– Deliverables
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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
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Thank you
• Any Questions?
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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
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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