P13222: FSAE Turbocharger Integration

Thursday, November 8th, 2012Kevin Ferraro, Phillip Vars, Aaron League

Ian McCune, Brian Guenther, Tyler Peterson

Detailed Design Review

Agenda

• Customer needs review • System architecture• Specifications overview • Review of compliance with requirements• Updated risk assessment • Testing Plans• Bill of Materials• Timeline/Schedule

Customer Needs Review

Customer Need # Importance Description

CN1 5 Overall Horsepower and Torque GainsCN2 5 Optimized ECU Map for Best PerformanceCN3 5 Consistent Engine PerformanceCN4 5 Necessary Engine Internals are Included with SystemCN5 4 Adequate System CoolingCN6 4 Sufficient Dyno Testing and ValidationCN7 4 Optimized Turbo Size for ApplicationCN8 4 Meet FSAE Noise RegulationsCN9 3 Quick Throttle Response

CN10 3 Easy to Access in CarCN11 3 Compact Design in CarCN12 3 Fit Within Constraints of Current ChassisCN13 2 Easy to DriveCN14 2 Drivetrain Components Designed for Power Increase

CN15 2 Design for Intercooler Location (if required)CN16 1 Readily Available Replacement PartsCN17 1 Simple Interface with Current EngineCN18 1 Maximized Use of Composite Material

Specifications Table

System Architecture

• Induction• Turbocharger• Boost control• Engine• Exhaust system• Mounting

Induction

Specification Value Compliance Verification

Mass air flow >= 50 g/s CFD Pressure measurements

Restrictor Diameter

<=20 mm Design Measure

Plenum Volume >=1000cc CAD, 3D modeling Volume measurement

Air temperature reduction

>= 50°F CFD, heat transfer analysis

Thermocouple measurement

Intake manifold pressure range

0-30 psi Design, component selection

Component pressure capacity will be tested during dyno data collection

Throttle Modulation

Near linear, Throttle position vs flow

CFD analysis Dynamometer measurement

Spike Throttle

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0

102030405060

0

20

40

60

80

100

New Linear Spike Results

Mass Flow Rate [g/s] Orig Mass Flow [g/s]Outlet Pressure [kPa] Orig Pressure [kPa]

Mas

s Flo

w R

ate

[g/s

]

Out

let P

Ress

ure

[kPa

]

Intercooler

CFD and GT-Power Simulation• Inlet, hot side: max spec

temp from turbine outlet• Inlet, cold side: ambient

environment

N=number of cells

Thickness

Width

TurbochargerSpecification Value Compliance Verification

Peak Power Output

60 hp, 45 ft*lbs

GT Power simulation DC Dynamometer measurement

Peak efficiency Efficiency maps,

GT Power simulation

DC Dynamometer measurement: Fuel consumption vs. power

Pressure to Actuate Wastegate

20 psi Purchased part Test stand measurement

Max Temperature of Turbo

<800°F Assumption: no modification from production part

Thermocouple measurement

Supplied Oil Pressure

170 kPa (24.7 psi)

Tapping into oil return line of engine

Oil pressure sensor, tapped into oil return line

Mass flow rate, compressor

>=40 g/s Compressor efficiency map

DC Dynamometer measurement

Mass flow rate, turbine

>=100 g/s Turbine efficiency map

DC Dynamometer measurement

Turbocharger

Boost Control

Specification Value Compliance Verification

Peak Power 60 hp, 45 ft*lbs

GT Power DC Dynamometer measurement

Pressure to actuate wastegate

20 psi Purchased part Bench-top testing

Maximum Boost level

30 psi Solenoid selection, flow rate calcs

Manifold air pressure sensor reading

Boost Control

Boost Control

Exhaust System

Specification Value Compliance Verification

Fit in the Car 1 Creo Solid modeling

Efficiency of turbine >40% GT-Power Dyno Testing

External Temperature

<800 °F GT-Power Dyno Testing

Bend Radius 3 in Creo Solid Modeling

Header Design

GT-Power Simulation

Mounting System

Specification Value Compliance Verification

Turbo axis of revolution orientation

Normal to gravity, ±10°

3D CAD Visual/Inspection

Oil outlet direction Parallel to gravity, ±35°

3D CAD Visual/Inspection

Connections to chassis

Compliance for CTE mismatch, vibration

Design and analysis Assembly, testing in operating conditions

Mounting

Risk Assessment ID Risk Item Effect Cause Likeliho

odSeverit

yImport

ance Action to Minimize Risk Owner

1 Poor Fuel Efficiency Low Fuel Economy Score Engine not tuned properly for endurance 1 3 3 Create separate fuel maps for each

individual event Powertrain Engineer

2 High Car CG Reduced Cornering Ability Turbo location not optimized 1 2 2Turbo placed within crash structure, allows for lowest placement possible

according to rules

Chassis Engineer/Structures

Engineer

3 Insufficient Oil Flow Blown Turbo/Short Turbo Life

Poor analysis of oil pressure source 2 3 6

Test oil pressure and flow of source prior to turbo implementation,

follow manfr's recommendations on oil supply

Powertrain Engineer

4 Thermal ManagementChassis, engine, seat, or

fuel over allowable temperature

Unexpectedly high heat generation 2 1 2

Analyze chassis airflow and design for cooling, design in flexibility for

additional cooling mechanisms

Chassis Engineer/Thermal

Engineer

5 Engine Vibration Turbo Mount Failure Insufficient structural analysis 1 2 2

Design with vibration in mind. Verify components are constrained

properlyStructures Engineer

6 Thermal Expansion Stresses Additional stresses on mounting components

Thermal CTE mismatch between exhaust

components and mounting components

1 2 2Design compliance into mounting

system to relieve thermal expansion stresses

Thermal/Structures engineer

7 Improperly Tuned Engine Poor overall engine performance

Lack of time to properly tune engine on dyno 2 3 6

Schedule must include plan to have plenty of engine testing time on the

dynomometerPowertrain Engineer

8 Lack of Available Space in Chassis Heavy plumbing and inefficient routing

Not all locations analyzed for optimal routing 2 1 2

All project members agree with location and plumbing plan prior to

implementation

Chassis Engineer/Structures

Engineer

9 Improper Turbo Size Poor overall engine performance

Inaccurate initial analysis and data acquisition 1 3 3

Use accurate and realistic parameters in engine simulation to

make best selection

Powertrain Engineer/Project

Manager

10 Welded Joint FailureStructural failure of

exhaust plumbing, release of exhaust gasses

Cracking/fracture of welded joints within exhaust

plumbing1 2 2

Use proper welding techniques to assure high quality weld. Mounting

system not to rely on support through welded sections.

Structures Engineer

11 Engine Failure Destroyed Engine Overboost, internal component failure 1 3 3

Use high-performance aftermarket components, reduce friction through coatings, control boost to acceptable

levelsPowertrain Engineer

Testing Plans

• Purchasing: Ti tube• Manufacturing: Throttle, plenum, plumbing• Initial setup/baseline• Dyno data collection, RPM sweeps:

Horsepower, torque, AFR, BSFC, throttle position, etc

• Labview: Dyno Controller software

Testing Plans

0.700000000000001 1.2-5

0

5

10

15

20

25

30

Torque vs. Lambda @ 7000 RPM

10%Polynomial (10%)20%Polynomial (20%)50%Polynomial (50%)100%Polynomial (100%)

Lambda (100 Octane)

Torq

ue (ft

*lbs

) @ V

aryi

ng Lo

ad

4000 5000 6000 7000 8000 9000 100000

10

20

30

40

50

WR450F Initial Power Curve

TQ (ft*lbs) HPHP_Post_Ign_Tune TQ_Post_Ign

RPM

Torq

ue (ft

*lbs

), Po

wer

(HP)

Bill of Materials

Bill of MaterialsAssembly Item Qty Description

Turbocharger Garret GT-06 1 Turbo Manifold Ti 1.5" .020" wall tube 10 ft Exhaust tubing Ti bellows 1 Exhaust bellows Ti .125" thick plate 2 ft^2 Plate for manifold flanges Ti o2 sensor bung 1 Bung for engine sensor Ti thermo couple bung 2 Bung for measureing exhaust gas temperatureMuffler Ti .062" thick plate 2 ft^2 Titanium plate for muffler ends Muffler packing 1 kg Fiber glass muffler packing Composite muffler can 1 6" diameter 18" long carbon fiber tubeIntake Intercooler core 1 6"x9" 1.5" thick heat exchanger core Composite intercooler tank 2 Endtanks for intercooler Al 1.5" .049 wall tube 10 ft Intake tubing 1.5" ID silicon hose 1 ft Intake tube joints Hose clamps 8 Intake joint hose clamps Al fuel injector bung 1 Fuel injector weld on bungTurbo Mount Mounting tube 3 ft .5" OD .035" wall 4130 tube MM-2 rod ends 3 6-32 rod ends

Timeline/Schedule