1. P13222: FSAE Turbocharger Integration
Kevin Ferraro, Phillip Vars, Aaron League
Ian McCune, Brian Guenther, Tyler Peterson
Kevin

2. Introduction
Turbocharger integration to improve scoring potential of 2013 car
GT-Power simulation
Used to select turbocharger
Assisted with intake and exhaust design
Used to simulate torque and fuel consumption map for Lap Time Simulator
Lap Time Simulator
Used to compare vehicle parameters to determine scoring tradeoffs
Shows that performance gain of turbocharging is worth the fuel efficiency and weight penalties
Aaron

3. Project Goals Select appropriate turbocharger for engine package
Design engine peripherals to maximize efficiency and power of powertrain
Utilize electronic boost control to enable tuning of fuel efficiency and power for each event via different engine maps
Comply with FSAE and FSG rules
Design and test for reliability and relatively easy maintenance
Tyler

4. Customer Needs Review Importance Description Was It Addressed? Ian 5
Overall Power and Torque Gains:
Yes, verified with simulation, needs to be verified on dyno
Optimized ECU Map for Best Performance
Optimized with simulation, will be finalized on dyno
Consistent Engine Performance
Will be addressed with repeated dyno testing
Necessary Engine Internals are Included with System
Yes-Carillo Rods and Swain Tech coated parts 4
Adequate System Cooling
Yes-intercooler and radiator sized properly
Sufficient Dyno Testing and Validation
Will be completed once fully assembled on dyno
Optimized Turbo Size for Application
Yes-Chosen using simulation results to avoid surge
Meet FSAE Noise Regulations
Will be determined once dyno testing begins 3
Quick Throttle Response
Simulated, will be validated by dyno testing
Easy to Access in Car
Yes-CAD shows this
Compact Design in Car
Fit Within Constraints of Current Chassis 2
Easy to Drive
Will be tested once on car
Drivetrain Components Designed for Power Increase
Yes, designers have used simulated values as design parameters
Design for Intercooler Location (if required)
Yes-CFD analysis confirms location is apt 1
Readily Available Replacement Parts
Some will have to be manufactured in house
Simple Interface with Current Engine
Yes – No modifications are required to interface
Maximized Use of Composite Material
Yes-Plenum, intercooler parts
Ian

5. Important Specifications
Function
Specification
Unit of Measure
Ideal Value
Comments/Status
Engine
Peak Power Output
HP and ft-lbf
>= 60HP, 45 ft- lbf
 62 HP Peak with 45 ft-lbf (GT-Power Model)
Intake
Mass Air Flow
g/s
>=40
 58 g/s Peak (GT-Power Model)
System
Overall Weight Increase
lbs
<=15
 Expected powertrain weight increase of <7 lb
Funding
Cost To Formula Team
$$$
<1000
Funding/sponsorship required
Compliance With FSAE Rules
N/A
No Infractions
Rules Compliant
Ian

6. System Architecture Induction Turbocharger Boost control Engine
Exhaust system
Mounting
Jack

7. Final Design
Jack

8. Final Simulation Model
Phil
GT-Power is a 1-D engine simulation software
Allows engine flow components to be modeled as 1-D approximations
Very good at simulating flow transients and resonances
Good at modeling Turbocharger system
Must be validated thru testing

9. Turbo Selection
phil
Comparison of GT0632 VS GT1238. GT12 is close to surge line until 6500 RPM. GT06 is near maximum efficiency until higher engine speeds.

10. Turbocharger Efficiency
phil
GT06 turbine operates close to peak efficiency over most of operating range
Compressor is near peak efficiency until higher engine speeds
This is acceptable since boost will be reduced at higher engine speeds anyway

11. Results From Simulation
Comparisons with Turbocharged (Red) and naturally aspirated powertrain (Blue)
Top Left: Power
Top Right: Torque
Bottom Left: Manifold air pressure
Bottom Right: BSFC
Phil

12. Transient Data
GT Power allows the simulation of transient flow characteristics
Can be used for simulation validation by making similar measurements on the Dyno
Can also be used to identify performance limitations
Cam profile is not ideal, however stock cams are better than Hotcam alternatives
phil
PV Diagram Mass Flow Thru Valves Static Pressure in Restrictor

13. Lap Time Simulation
Lap Time Simulator used to find scoring potential of possible configurations
Shows that performance gain of turbocharger outweighs fuel efficiency and weight penalties
Kevin

14. Turbocharger Modifications
tyler
Flange modifications:
Weight savings of 883g
Allowed mounting to single port for single cylinder engine (designed for two cylinder diesel)

15. Turbocharger-Mounting
Needs:
positioned and constrained robustly
allow for thermal expansion
isolate from vibration to maximum degree possible
follow turbocharger specs for proper lubrication to ensure longevity
aaron
Structural analysis
Modal analysis
Verification through testing

16. Intercooler Size-based off intake flow rate and packaging constraints
GT Power model simulated effect on overall system
Needs to be verified with test data
CFD analysis-ensure proper airflow based on full car location
CFD analysis-shroud design for maximum efficiency
kevin

17. Intercooler-Modification
Material removal from intercooler core resulted in 192.2g weight reduction
Additional weight savings with carbon fiber end tanks
kevin

18. Intake/Fuel Delivery
Intake shape-packaging constraints, desired volume, runner length
Utilized DOE within GT Power for iterative analysis
Plenum diameter varied 3-8 inches-5.5” chosen-packaging/performance compromise
Runner varied 5-12 inches-9” chosen-packaged better than slightly better 12” length
CFD analysis-verify no unusual flow patterns
Cone geometry of injector spray based on data from Delphi
2 stage injection system
Primary (near intake port) improved starting, low speed operation
Secondary (plenum) maximize atomization at high speeds, minimize wall wetting
ian

19. Intake/Fuel Delivery Cont’d
ian

20. Electronic Boost Control
Needed to allow tuning flexibility-boost varied for different events
Three-way solenoid in-line between manifold pressure and wastegate diaphragm, vented to atmosphere
Solenoid controlled via PWM from ECU according to a PID control algorithm to achieve desired boost level
jack

21. Exhaust DOE utilized within GT Power Header length varied .5-3.5”
3.5” best, 2.5” chosen-packaging
Exhaust length varied .5-8”
Minimal effect on performance
Header bomb simulated
Minimal effect on performance-not adopted
Thin walled (.020”) Commercially Pure Grade 2 Titanium chosen for exhaust
High working temp
Low density
tyler

22. Exhaust Cont’d
tyler

23. Engine
Phil

24. Budget Total: $1,964.00 Purchased Items Item Cost Jack
GT-0632SZ Honeywell Turbocharger
$680.00
Intercooler core material
$260.00
Sheet aluminum, intercooler end material
$50.00
Exhaust plumbing material
$250.00
Intake plenum mold material
$40.00
Boost Control Selonoid
$100.00
External Engine oil piping, hose, fittings
Crank Bearings
Carillo Connecting Rods
$484.00
Total:
$1,964.00
Jack
Mention Cost event as well

25. Testing
Testing to begin on DC Motor Dynamometer as soon as remaining components are manufactured
Dyno setup modified to accommodate intake and exhaust systems
Testing/tuning with actual components-delayed start, but save manufacturing time/cost, more accurate validation, calibration
Measurements will include:
Torque
Engine Speed
Crank Angle
Cylinder Pressure
Temp and Press will be measured at:
Intake Before Intercooler
Intake After Intercooler
Intake Plenum
Exhaust Near Exhaust Port
Exhaust After Turbine
Data logging will be once per degree of crank angle to verify transients
phil

26. Lessons Learned
Engine simulation allowed for single iteration of manufacturing-saves time/resources-depends on simulation accuracy
Simulation results sensitive to input parameters- many initially unverified
Power generated is knock-limited (no feasible way to simulate)
Scoring potential trade-off between fuel efficiency and lap time depends on performance of fastest car at competition
aaron

27. Future Work Finish manufacturing Complete testing
Verify simulation, change parameters if necessary to ensure accurate future simulations
Make multiple ECU maps for different events
Install in car
Tune based off driver feedback
Ensure noise level meets regulations
Win at competition
ian