Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski

William Mehnert

Overview• Project Objectives• Project Goals• Project Background• Design Approach• Conceptual Design• Ignition Timing• Fuel Control• Closed Loop Control• Deliverables• Equipment needed• Budget• Nugget Chart• Project Management• 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

Project Goals

• Design a kit for the public to use without major modification to the engine

• Understand the benefits of alternative fuels and the behavior of the engine using Ethanol-gasoline blends

• Understand the effects of the different blends up to E85

Project Background

• Ethanol vs. gasoline– Octane number– Brake Specific Fuel

Consumption– Heating Value

• Production and Availability

• Environment Protection Association standards

• Existing products

Design Approach

• Engine Option– 1 cylinder Briggs

and Stratton

 Engine Configuration

3.5 HP air cooled, 4 stroke, horizontal engine

 Engine Displacement 9.02 cu. In.

Max speed 4000 rpm

 Bore x Stroke 2.56 x 1.75 in

 Fuel Delivery System Float type carburetor

Design Approach (contd)

• Engine Options– 1998 Suzuki

GSXR 750cc– Open loop ECM

 Engine Configuration Inline Four, 4-Stroke,

DOHC

 Engine Displacement  749 cc

 Compression Ratio  11.8:1

 Valves Per Cylinder  4

 Bore x Stroke  72 x 46 mm

 Measured Peak Horsepower  135 bhp @ 12,500 rpm

 Measured Peak Torque

 62 lbs. - ft. @ 10,00 rpm

 Combustion Chamber Volume  17.3 cc

 Fuel Delivery System  Fuel Injection

 Ignition System  Digital Electronic

Design Approach (contd)

• Engine Option– 2001 Suzuki

GSXR 600cc

– Closed loop ECM

 Engine Configuration Inline Four, 4-Stroke,

DOHC

 Engine Displacement  599 cc

 Compression Ratio  12.2:1

 Valves Per Cylinder  4

 Bore x Stroke  67 x 42.5 mm

 Measured Peak Horsepower  115 bhp @ 12,500 rpm

 Measured Peak Torque

 69 lbs. - ft. @ 10,000 rpm

 Fuel Delivery System  Fuel Injection

 Ignition System  Digital Electronic

Design Approach (contd)

• Ignition timing Control– ECM: control spark timing and fuel– Encoder or crank angle sensor: measure

crank angle to adjust timing

• Control system design– Flex Fuel Sensor: Ethanol-Gasoline blend– Exhaust Gas Temperature: Optimize

timing

– O2 content sensor: Detect complete burn

Why concentrate on Ignition Timing?

• Directly affects combustion temperature

• Combustion temperature affects emissions

• Main cause of engine knock or pre-detonation

• Effects power output• Must be adjustable to compensate for

different blends of Ethanol-Gasoline

Ignition Timing

• Measured as degrees before Top Dead Center

• Must leave time for flame propagation

• Early ignition creates high pressures and engine knock leading to failure

• Late ignition leads to poor power output

Fuel Control

• Directly affects Horsepower (heating value of fuel)

• Adjust Air/Fuel ratios for proper combustion/emissions

http://www.rceng.com/technical.aspx?UserID=230225&SessionID=SiEH2zhKsmej8veflxBT

Feedback

• Oxygen Sensor– Adjust fuel consumption

• Flex Fuel Sensor– Determine ethanol mixture– Winter and summer blends, etc

• Exhaust Gas Temperature– Chamber temperatures lead to detonation– Risk of melting internal components

• Emissions– High temperature leads to high NOx– Low temperature leads to high HC

Closed Loop system

• FFS used for primary ignition table

• Sensors used for trim values

Deliverables

• Emissions readings– CO– NOx– HC

• Torque (HP Calculated)

• Fuel Consumption

• Sensitivity Analysis

Equipment Needed

• Engine – Fuel Injected with Electronic Timing

• ECM – Megasquirt or Equivalent

• Sensors – FFS, EGT, O2

• Dynamometer (Time) – Outsourced

Budget

Area ofCommodity

Part Name/Labor Quantity Price/Part and Labor Total Cost

Engine Engine 1 $1,500.00 $1,500.00

Engine Injectors 4 $50.00 $200.00

Control system ECM 1 $700.00 $700.00

Sensor Flex Fuel Sensor 1 $600.00 $600.00

Sensor Wideband 1 $200.00 $200.00

Sensor EGT 1 $150.00 $150.00

Testing Dynamometer 6h $80.00/h $480.00

Shipping andhandling Shipping 5 $30.00 $150.00

Total $3,980.00

Nugget Chart

Project Management

• Task Management– Research – Product Development

• Refinement• Architecture

– Engineering, tuning and testing– Deliverables

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

Thank you

• Any Questions?

Sensitivity Analysis

• Timing vs. ALL– Use conservative Air/Fuel Ratios and

measure against all Parameters for a specific RPM

• Fuel vs. ALL– Use steady timing and measure all

parameters for a specific RPM

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• 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