SAE Clean Snowmobile Challenge Design Presentation 2019 SAE

SAE Clean Snowmobile Challenge Design Presentation 2019 SAE

SAE Clean Snowmobile Challenge Design Presentation 2019 SAE Clean Snowmobile Challenge Rochester Institute of Technology Clean Snowmobile Team Jeff Phelps and Lucas Miller Agenda Introduction Chassis

Engine Team organization Overview of Design Process Project Planning Solutions Muffler Redesign Throttle body sizing

Calibration strategy Flex Fuel Conclusion Questions Introduction Presenters Jeff Phelps School Status: 4th year

Role: Project Manager Major: Mechanical Engineering Technology Lucas Miller School Status: 5th year Role: Engine Tuning & Calibration Major: Mechanical Engineering

Technology Team Chassis 2016 Polaris Rush pro-s Curve Industries xs skis Increased front spring rate Engine

Manufacturer: Weber Displacement: 749cc Usage: Polaris FS IQ Touring Stroke: 4 Compression Ratio: 11.5:1 Injection: Multi-Port Injection Fuel Source: Gasoline Stock Power: 80 HP Team Structure Overview of Design Process

Using the 2018 CSC as a baseline for the 2019 design season, the team utilized the experience to identify key issues and low scoring categories. The DMAIC process has been used for multiple years as it allows a clearly defined workflow throughout the year for each of the groups within the team. Project Planning 2018 Benchmark Muffler Issues High noise levels Bolt in catalyst loosening Oil leak issues

AN fittings vibrating loose Engine mounting issues Improper clutch spacing Inability to Cold Start Idle issues Solutions Approaches selected Muffler Issues- Full Redesign Oil leak issues- switch back to hose clamps Engine mounting issues-Engine Mount Redesign Inability to Cold Start- logging starts

Idle issues- Reduce throttle body size Muffler Design- Components Inner Cone with cut out slots Outer Cone to guide the reverse flow Catalytic Converter Perforated Tube wrapped with glass fiber sound absorbent packing material Inlet and Outlet pipes Muffler Design-Flow

Inlet Flow through Catalytic Converter to Inner Cone with Slots Flow exits slots from inner cone and is guided back by the outer cone Flow escapes outer cone through a gap between the face of the outer cone feature and the top inner wall of the shell Flow circulates in the top chamber and exits through

the perforated tube Muffler Design- Sound Wave Flow Principles Cones act as a baffling device by reducing the volume of the entering sound waves Sound waves reflect off the cone, interfering with the entering sound waves, cancelling each other out Reducing the size of the slots in the cone benefits the sound dampening

Reducing the gap distance between the outer cone feature and the top inner shell wall limits the amount of flow that can escape, reducing the noise Perforated tubes dissipate the sound wave energy by converting them to heat energy through frictional dampening via the perforated holes Sound absorbent packing material reduces the high pitch sound waves Throttle Body Size Reduction

Idle was too high during 2018 comp This allowed for lower clutch engagement speed No decrease in peak power was seen No vacuum leaks were identified Throttle position at idle was at minimum Switch to a smaller throttle body (54mm to 46mm)

Engine Calibration Strategy Stoichiometric for cruising loads and speeds Increased fueling outside of typical cruising range Decreased Nox Decreased Cylinder Temperatures and Increased Reliability

Data Logging Increased power Used to refine initial fuel table from dyno Knock Sensor used for spark and fuel correction for Ethanol Flex Fuel Closed Loop O2 is utilized to allow the engine to run any type of fuel from E0 to E85 gasoline/ethanol mix ECM reads lambda and adjusts fuel pulse width in order to maintain stochiometric conditions

ECM has the ability to learn pervious engine operating parameters to adjust pulse width quicker Accidental testing shows that the engine is not capable of switching to a gas/ethanol/diesel mixture using this approach Conclusion A reduction in noise and emissions was attained Rider comfort and appearance were maintained Technologies utilized Engine swapped 3d printed Intake

Custom designed and fabricated exhaust system Engine tuning & dynamometer time Questions?

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