Team FSAE Powertrain

Transcription

1 Senior Design Final Project Presentation Team FSAE Powertrain Presented By: Michael Honeychuck, William Jay Kistler, Nick Piacente, Adam Stager December 13 th 2010

2 Supervisors Team Sponsor: Mr. Paul Schwarz Mainline Porsche, Newtown Square, PA Team Faculty Advisor: Dr. Steve Timmins University of Delaware, ME Department

3 General Project Info To aid in the production of the powertrain for the SAE car to compete in the annual FSAE competition next summer in California. What is the Powertrain? Constraints/Needs Must spend less then $1000 Must adhere to all 2011 FSAE Competition Rules Must complete objectives prior to semester end (December 17 th ) Finish all dynamic events at FSAE competition Overall Customer Wants Minimize Weight Maximize Durability/Reliability Enhance Aesthetics/Neatness/Workmanship Maximize Performance

4 Final Project Scope As the SAE Powertrain Team, we are responsible for designing and developing reliable support systems for the engine and transmission on the UD SAE car. The other main project goal was to develop detailed plans and procedures for continued development within the UD SAE club. Our project was divided into 3 subsystems: 1. Drivetrain 2. Air System 3. Engine Cooling

5 Final Project Deliverables Drivetrain Limited slip differential with custom housing and mounting 2 rear axles 2 rear hubs 2 aluminum axle/hub spacers Air System Prototype air intake Prototype exhaust Engine Cooling radiator electric pull fan Plans for radiator/fan duct work

6 Final Product Overview

7 Project Aspect 1: Drivetrain Transfer engine s torque through differential, axles, and hubs, to drive wheels

8 Differential: Final Product Purchased Honda TRX ATV limited slip differential Used stock geometry and mounting locations Manufactured aluminum carrier, uprights, connectors, adapters

9 Differential: Exploded View Honda TRX Limited Slip Differential 2. Differential Housing 3. Housing O-ring Seals 4. Drain Bolt and Seal 5. Hardware Seals 6. Hardware Press Fit Adapter 8. Sprocket 9. Bearing 10. Upright Connections 11. Axle Seals 12. Uprights

10 Differential: Validation of Metrics Method Target Metric Old New Savings Cost --- <$600 $628 $534 Weight Scale <7 lbs 7.75 lbs 6.10 lbs Total Assembly Length Durability Calipers <10 inches inches 4.96 inches Evaluation No Leakage present not fully tested $94.00 (14%) 1.65 lbs (21%) 5.29 inches (51%) ---

11 Differential: Testing and Validation Upright Stress Test (Bearing Seize) 17, , , , , , , , Initial Filling and Spin Test -More than 25% of total internal volume filled -Spun for 50 turns Factor of Safety Greater than two

12 Differential: Path Forward Final testing will take place during Winter Session 2011 Mimic conditions of 45-minute endurance event Check for oil leakage a: Application specific seals b: O-ring face seals c: Press fits

13 Rear Axles: Final Product (2) 18 Honda TRX ATV axles (Purchased) Axles cut, 4130 Steel extensions added for length ATV axles press fit into extension using an acetylene torch for thermal expansion Welded at four points over the press fits of each axle

14 Rear Axles: Testing and Validation Manufacture four test axles, and testing apparatus Apparatus fixed to platform in the Instron machine in Spencer Laboratory, tension force applies to wire rope, which creates a moment through the lever arm to the test main shaft

15 Rear Axles: Testing and Validation Find maximum allowable torque input, failure mode Torque before failure: 335 ft-lbs (target 168 ftlbs) Failure Point press fit and weld points axle shaft slips relative to the extension

16 Rear Axles: Validation of Metrics Cost Target Metric <$1,000 as a team Old New (Left Axle New (Right Axle) Savings $ $ $ $1, Weight 6.9 lbs 6.9lbs lbs 0.6lbs 20 ft-lbs Allowable Static Torque Less than 1 degree 0.68 degrees 0.61 degrees 0.82 degrees Insignificant 168 ft-lbs ft-lbs 335 ft-lbs ---

17 Rear Axles: Path Forward Can be permanently pressed into differential and rear hubs once hubs are completed

18 Rear Hubs: Geometric Constraints

19 Hubs: Final Product (2) Machined and welded 4130 steel hubs, 3 part assembly (2) Machined aluminum wheel guides (2) Purchased Taylor Racing Products 64mm wheel bearings Hardware

20 Rear Hubs: Validation FEA Simulation Static Stress Tests: Resting Acceleration Braking Mode 1 Braking Mode 2 Cornering Factor of Safety Fatigue Tests: Braking Mode 2 Failure after 33hrs Cornering Failure after 28hrs Cost Minimized: $130 (after splining and heat treating) Weight Minimized: 3.1lb each

21 Rear Hubs: Path Forward Have hubs heat-treated and broached (internally splined) at RCV Performance over Winter Session 2011 Press lug bolts and wheel bearings in place Complete upright assemblies with components from suspension Install on car and observe performance

22 Project Aspect 2: Air System Allows engine to breath via air intake and exhaust Intake must include 20mm restrictor to limit power Intake must be inside blue pyramid Exhaust must maintain engine noise <110dB

23 Air Intake: Final Product (1) Prototype air intake with adjustable plenum and runner tube Throttle Body With Throttle Actuator and Position Sensor Mass Air Flow Sensor Port Engine Mount Flange Fuel Injector Mount Double Conical Air Filter Expandable Runner Velocity Stack Mandatory 20mm Restrictor Expandable Plenum

24 Air Intake: Validation Car New Prototype Air Filtration Area 17.69in in 2 Plenum Volume 2.5*511cc [2.5*511cc:5*511cc] Runner Length 13.3in [11.3in:17.3in] Post Restrictor Component Order Fuel Injector Position Minimized Cost: $110

25 Air Intake: Path Forward Utilize adjustable intake for tuning/performance tests on dyno during winter session 2011 examining Horsepower and Torque versus RPM to find optimum plenum volume and runner length. Use CFD software to optimize design Manufacture final air intake Install on car and observe performance

26 Exhaust: Final Product Expandable Exhaust Prototype Stainless Steel Expandable Main Tube (1-5/8 OD) Expandable from (Total Exhaust Length) Uses copper insulating wrap to reduce heat in the engine bay. FMF Q4 muffler

27 Exhaust: Final Product Noise Function of airflow out of exhaust valve, length of primary tube, outer diameter and thickness of the tube, number of bends, size and efficiency of the muffler All materials for prototype were given from FSAE

28 Exhaust: Future Testing and Validation Noise Test: Test for exhaust noise following the guidelines of the FSAE noise test, at optimal air intake size and proper engine tuning Noise readings taken in decibels at 10,500 RPM 110 db constraint Previous Exhaust 28 primary length, passed noise test last year at competition Expandable Exhaust primary length Compromise between noise and power based on length of primary tube

29 Exhaust: Path Forward Increase muffler sound dampening qualities - repack muffler gauze Perform noise tests at varying main tube lengths once the final air intake is manufactured and the engine is properly tuned

30 Project Aspect 3: Cooling Must use plain water as engine coolant

31 Engine Cooling: Final Product Yamaha YFZ450 radiator Derale Cooling Products 7 Tornado Push/Pull Fan 4 feet of 1 OD rubber heater hose Pressure relief valve on engine Radiator bolted to right side of chassis

32 Engine Cooling: Testing car Inlet Port Let car reach operating temperature Inlet/outlet temperature readings were taken from radiator Readings taken at idle (3,500 RPM), half throttle (6,500 RPM), and full throttle (10,500 RPM) Performed with electric fan inches behind radiator Outlet Port

33 Engine Cooling: Validation of Metrics Target Metric Old System New System Savings Cost <$ $9 --- Total Weight <5 lbs 4.75 lbs 4.25 lbs 0.5 lbs (12%) Volume Space < 1,872 cubic inches (8 x13 x18 ) 500 cubic inches (10 x10 x5 ) 1,465 cubic inches (7.4 x11 x18 ) none Heat Dissipated >17,000 W 16,861 W 20,753 W 3,892 W (23%) Fan Amperage Draw <5 A A ---

34 Engine Cooling: Path Forward Detailed ducting designs are available for composite material manufacturing over Winter Session 2011

35 Special Thanks We would like to give a special thanks to the following people and businesses: Ernie Martelli, Martelli s Metal Fabrication Ivyland, PA Adam Kinzey and Doug Brunner UD fuel cell laboratory Steve Beard UD ME student machine shop PowerSports East Bear, DE RCV Performance Loves Park, IL CMX Ivyland, PA Dale Cherry, Injection Connection Horsham, PA

36 Thank you for attending our presentation. What questions can we answer?

37 Applicable 2011 FSAE Rules Must use a 4-stroke engine, up to 610 cc piston displacement Air intake must lie within space defined by top roll hoop and outside edges of tires A maximum 20-mm restrictor must be placed inside air intake between throttle and engine Must use water as engine coolant Exhaust components must be less than 45 cm behind rear axles and less than 60 cm above the ground Maximum permitted exhaust level is 110 db

38 Starting Point: UD SAE Car Single Cylinder, 511-cc Yamaha YFZ450 ATV engine, rear mounted, chain drive High Power-to-Weight Ratio