Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski
William Mehnert
Overview• Project Objectives• Phase Overview
– Phase 1– Phase 2
• Bill of Materials• Component Overview• Software Flow Chart• Program Logic• Test Bed• Nugget Chart• Conclusion
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
Phase 1 Overview
• Evaluation of design approaches (different engines)
• Research of existing products• Ignition timing is most important aspect of
performance
Phase 2 Overview
• Areas of Technical Analysis– Ignition Timing– Explosion Limits– Emissions– Power/Torque
Bill of Materials
• Total = $3,279.50
Component From Price Function
Megasquirt (ECM) DIYAutotune.com $436 Engine Control
Exhaust temperature lethaldiesel.com $78 Timing Control
Oxygen Sensor Summitracing.com $200 Air/Fuel Ratio Control
Flex Fuel Sensor Gmpartsdirect.com $363 Fuel Composition
Fuel Injector Summitracing.com $250 Fuel adjustments
Engine E-bay or other used parts market place
$1200 Testing
Dynamometer Local performance shop $80/test Testing
Emissions Local testing center $80/test Testing
E85 Fuel Closest E85 Station $2.75/Gallon Fuel
Misc Sensors and Circuits
Mouser.com or Digikey.com $165 Control Circuits
*Prices do not include taxes and shipping fees.
Component Overview
• Megasquirt – Standalone ECM– Allows for full programmability and control
of all engine parameters– Allows for development of control
algorithms
Component Overview• EGT Sensor
– Detects exhaust gas temperature (Chamber temperature)
Oxygen Sensor, wideband
-Detects air/fuel ratio
Component Overview• Flex Fuel Sensor
– Detects ethanol content in the fuel
Software Flow Chart
ECM
Exhaust Gases
FFS Fuel
Injectors Ignition O2 EGT
Program Logic
• Read FFS to determine ethanol content– Trim fuel table and timing table to compensate
• Read Oxygen Sensor– Trim fuel values to bring values back to
stoichiometric or towards desired target• Read EGT sensor
– Trim timing values to adjust EGT temperatures to acceptable range and reduce emissions.
• Check throttle position– Adjust timing and fuel lookup tables to create
power as demanded.
Test Bed
• Track of dyno – 24”-96”– Track of current SAE car - ~62”– Used to tune vehicle for power, torque, and
emissions
• 5 Gas emissions testing
Nugget Chart
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
• The testing will consist of two identical runs; one with gasoline and one with E85
• The results will be directly compared to determine to the differences in the theoretical values vs. the actual values.
Thank you
• Any Questions?
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• http://www.eng-tips.com/viewthread.cfm?qid=33615• http://www.engineeringtoolbox.com/explosive-concentration-limits-d_423.html• http://www.allpar.com/fix/EPAMethods.html• http://www.techedge.com.au/vehicle/wbo2/wblambda.htm• 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
Chemical Equilibrium
• Gasoline – C8H18+12.5(O2+3.76N2)
CO2+3H2O+12.5(3.76N2)
• Ethanol– C2H5OH+3(O2+3.76N2)
2CO2+3H2O+3(3.76N2)
Formulas Used