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Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski William Mehnert Overview • • • • • • • • • • • • Project Objectives Project Review Future Considerations Testing and Instrumentation Lab Testing Equipments Instrumentation Setup Hardware Selection Hardware Modification Software Modification Design of Experiments Nugget Chart Gantt Chart Project Objectives • Provide a control unit that will allow a gasoline engine to operate on E85 without sacrificing fuel consumption, performance, and emissions by optimizing operation parameters on the fly to create an efficient flex fuel option. • Develop and execute testing procedures to accurate assess and compare the performance of the engine operating either gasoline, E85, or any other blend. Project Review • Phase I – Conceptual Design/State of the Art Review • Phase II – Technical Analysis (Ignition Timing) • Phase III – Final Design Proposal and Budget • Phase IV – Order Components, Sponsorship, Integration of Major Components, – Testing preparation and accommodations Future Considerations • Completion of Prototyping and Testing • Build a strong foundation for future design groups and Formula SAE competition groups • Useful resources that can be utilized in lab experiments • Optimization of programming for better execution • “Plug and Play” design for easier installation in factory vehicles – Install only EGT and Flex Fuel sensor – Interrupt and adjust Ignition Timing and Fuel injection • Reduce the size of the unit Testing and Instrumentation • Testing requirements – Ability to move the testing space to the testing facility – Placement of data acquisition equipment on the testing space – Ability to easily remove the data acquisition equipment – Knowledge of dynamometer and gas emissions equipment – Prediction and verification of dynamometer results Lab Testing Equipments • Sensors – Gas flow and air flow meter – Intake pressure sensor – Cylinder pressure • Emissions Analyzer • Dynamometer • Data Acquisition component http://carambola.usc.edu/Research/TPCE/TPCE.html Instrumentation Setup • Sensors – Flow measurement • Fuel measurements – Temperature Sensors • Exhaust Gas Temperature • Coolant temperature • Intake temperature – Pressure Sensor • MAP – Crank Angle Sensor – Oxygen Sensor • Measure the amount of Oxygen at the exhaust • Correct the amount of fuel – Wideband Sensor • A/F ratio – FlexFuel Sensor • Fuel blend – Throttle position sensor Hardware Selection • Megasquirt II v.3.0 – Allows for ignition and fuel adjustments based on RPM, Throttle Position, Coolant Temperature, Air Temperature, and Air density – Contains prototype area to build custom circuits • Innovate Wide-band Oxygen Sensor – Most cost effective unit on the market – Output directly into the Megasquirt unit Hardware Selection • K-Type Thermocouple (EGT) • GM Flex Fuel Sensor • Megasquirt Stimulator v.2.2 – Allow testing of feedback functionality without risk of damaging critical engine components • Sponsorship by Hardware Modification • Flex Fuel Sensor – Added resistor to circuit • Exhaust Gas Temperature Sensor – New separate circuit built in prototype area of board Software Modification Open source • Added gauges • Added features for data acquisition • Need to add closed loop control for EGT feedback Design of Experiment PHASE ONE: Sensitivity Analysis • Open loop testing – Timing • Testing for – Horsepower/Torque – Emissions – Fuel swap and A/F adjustment • Testing for: – Horsepower/Torque – Emissions Design of Experiment PHASE TWO: Sensitivity Analysis and Optimization • Closed loop testing – A/F ratio • Optimization of target values – EGT • Optimization of ignition timing • Optimization of emissions Design of Experiment PHASE THREE: Results and Conclusion • E85 Performance Map • Comparison Matrix • Recommendations for future studies • Future of E85 as a reliable alternative fuel source Nugget Chart Gantt Chart Thank you • Any Questions? Reference • www.change2E85.com • www.megasquirt.info • www.e85fuel.com • http://carambola.usc.edu/Research/TPCE/TPCE.html • Internal Combustion Engines, C. Ferguson and A. Kirkpatrick, second edition