Senior Design Final Project Presentation

Team FSAE Powertrain

Presented By: Michael Honeychuck, William Jay Kistler, Nick Piacente, Adam Stager December 13th 2010

Supervisors
Team Sponsor:

Mr. Paul Schwarz Mainline Porsche, Newtown Square, PA

Team Faculty Advisor:

Dr. Steve Timmins University of Delaware, ME Department

General Project Info

To aid in the production of the powertrain for the 2010-11 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 17th) Finish all dynamic events at FSAE competition

Overall Customer Wants

Minimize Weight Maximize Durability/Reliability Enhance Aesthetics/Neatness/Workmanship Maximize Performance

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 2010-11 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

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

Final Product Overview

Project Aspect 1: Drivetrain

Transfer engines torque

through differential, axles, and hubs, to drive wheels

Differential: Final Product

Purchased Honda TRX ATV

limited slip differential

Used stock geometry and

mounting locations
Manufactured aluminum

carrier, uprights, connectors, adapters

Differential: Exploded View

1. 2. 3. 4. 5. 6. Honda TRX Limited Slip Differential Differential Housing Housing O-ring Seals Drain Bolt and Seal Hardware Seals Hardware 8 12 11 9 7 3 6 10 3 3 4 6 6 5 2 7. Press Fit Adapter 8. Sprocket 9. Bearing 10. Upright Connections 11. Axle Seals 12. Uprights 2 1 6 4 5 6 7 9 12 11

Differential: Validation of Metrics

Method
Cost --Target Metric <$600

Old
$628

New
$534

Savings
$94.00 (14%) 1.65 lbs (21%) 5.29 inches (51%)

Weight
Total Assembly Length

Scale
Calipers

<7 lbs

7.75 lbs

6.10 lbs

<10 inches 10.25 inches 4.96 inches No Leakage

Durability

Evaluation

present

not fully tested

---

Differential: Testing and Validation

Upright Stress Test (Bearing Seize)
17,700.4 14,225.4 13,275.3 10,325.3 8,850.2 7,375.2 5,900.2 2,950.1 0.1

Initial Filling and Spin Test -More than 25% of total internal volume filled -Spun for 50 turns

Factor of Safety Greater than two

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

Rear Axles: Final Product

(2) 18Honda 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

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

Rear Axles: Testing and Validation

Find maximum allowable torque input, failure

mode
Torque before failure: 335 ft-lbs (target 168 ft-

lbs)
Failure Point press fit and weld points axle

shaft slips relative to the extension

Rear Axles: Validation of Metrics

Target Metric Cost Weight Deflection @ 20 ft-lbs Allowable Static Torque <$1,000 as a team 6.9 lbs Less than 1 degree 168 ft-lbs

Old $1775.60 6.9lbs 0.68 degrees ---

New (Left Axle $122.47 6.3 0.61 degrees 335 ft-lbs

New (Right Axle) $122.47 6.9 lbs 0.82 degrees 335 ft-lbs

Savings $1,530.66 0.6lbs Insignificant ---

Rear Axles: Path Forward

Can be permanently pressed into differential and rear hubs

once hubs are completed

Rear Hubs: Geometric Constraints

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

Rear Hubs: Validation

FEA Simulation
Static Stress Tests:
Resting Acceleration Braking Mode 1 Braking Mode 2 Cornering

Factor of Safety

19.4

5.83

7.37

2.78

2.64

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

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

Project Aspect 2: Air System

Allows engine to breath via

air intake and exhaust

Intake must include 20mm

restrictor to limit power pyramid

Intake must be inside blue

Exhaust must maintain

engine noise <110dB

Air Intake: Final Product

(1) Prototype air intake with adjustable plenum and runner tube
Engine Mount Flange Throttle Body With Throttle Actuator and Position Sensor Double Conical Air Filter Mass Air Flow Sensor Port

Fuel Injector Mount

Expandable Runner

Mandatory 20mm Restrictor Velocity Stack

Expandable Plenum

Air Intake: Validation

09-10 Car Air Filtration Area Plenum Volume Runner Length 17.69in2 2.5*511cc 13.3in New Prototype 43.24in2 [2.5*511cc:5*511cc] [11.3in:17.3in]

Post Restrictor Component Order

Fuel Injector Position Minimized Cost: $110

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

Exhaust: Final Product

Expandable Exhaust

Prototype Stainless Steel Expandable Main Tube (1-5/8 OD) Expandable from 27 35 (Total Exhaust Length) Uses copper insulating wrap to reduce heat in the engine bay.
FMF Q4 muffler

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

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

27 35 primary length
Compromise between

noise and power based on length of primary tube

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

Project Aspect 3: Cooling

Must use plain

water as engine coolant

Engine Cooling: Final Product

2004-05 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

Engine Cooling: Testing

2009-10 car Let car reach operating Inlet Port

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 2009-10 electric fan 0.375 inches behind radiator

Outlet Port

Engine Cooling: Validation of Metrics

Target Metric
Cost Total Weight <$15 <5 lbs

Old System New System

--4.75 lbs 500 cubic inches (10x10x5) 16,861 W --$9 4.25 lbs 1,465 cubic inches (7.4x11x18) 20,753 W 4.8A

Savings
--0.5 lbs (12%)

Volume Space
Heat Dissipated Fan Amperage Draw

< 1,872 cubic inches (8x13x18)

>17,000 W <5 A

none
3,892 W (23%) ---

Engine Cooling: Path Forward

Detailed ducting designs are available for composite material

manufacturing over Winter Session 2011

Special Thanks
We would like to give a special thanks to the following people and businesses:
Ernie Martelli, Martellis Metal FabricationIvyland, PA

Adam Kinzey and Doug Brunner UD fuel cell laboratory

Steve BeardUD ME student machine shop PowerSports EastBear, DE RCV PerformanceLoves Park, IL CMXIvyland, PA Dale Cherry, Injection ConnectionHorsham, PA

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

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

Starting Point: 2009-10 UD SAE Car

Single Cylinder, 511-cc

Yamaha YFZ450 ATV engine, rear mounted, chain drive

High Power-to-Weight

Ratio