1. Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski William Mehnert

2. 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

3. 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

4. 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

5. Project Background Ethanol vs. gasoline –Octane number –Brake Specific Fuel Consumption –Heating Value Production and Availability Environment Protection Association standards Existing products

6. Design Approach Engine Option –1 cylinder Briggs and Stratton Engine Configuration 3.5 HP air cooled, 4 stroke, horizontal engine Engine Displacement9.02 cu. In. Max speed4000 rpm Bore x Stroke2.56 x 1.75 in Fuel Delivery SystemFloat type carburetor

7. 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

8. 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

9. 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 –O 2 content sensor: Detect complete burn

10. 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

11. 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

12. 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

13. 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

14. Closed Loop system FFS used for primary ignition table Sensors used for trim values

15. Deliverables Emissions readings –CO –NOx –HC Torque (HP Calculated) Fuel Consumption Sensitivity Analysis

16. Equipment Needed Engine – Fuel Injected with Electronic Timing ECM – Megasquirt or Equivalent Sensors – FFS, EGT, O 2 Dynamometer (Time) – Outsourced

17. Budget Area of Commodity Part Name/ LaborQuantityPrice/Part and LaborTotal Cost Engine 1$1,500.00 EngineInjectors4$50.00$200.00 Control systemECM1$700.00 SensorFlex Fuel Sensor1$600.00 SensorWideband1$200.00 SensorEGT1$150.00 TestingDynamometer6h$80.00/h$480.00 Shipping and handlingShipping5$30.00$150.00 Total$3,980.00

18. Nugget Chart

19. Project Management Task Management –Research –Product Development Refinement Architecture –Engineering, tuning and testing –Deliverables

20. 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

21. Thank you Any Questions?

22. 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

25. 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