Formula SAE Flow Testing Device Team members:Keith LundquistLong DangAdam BarkaVu NguyenJasper Wong

Industrial Advisor: Academic Advisor:Evan Waymire, PE Chien Wern, PhD

Outline

1. IntroductionBackground – Need – Mission Statement

2. Design Requirements3. Top Level Design4. Design Analysis5. Final Design and Prototype6. Verification7. Conclusion

Background

Formula SAE®

• Student DesignCompetition

• Open-wheel,Formula style race car

• Engineering + Business

Need

• Flow coefficients for 1-D simulations (valves and orifices)

• Direct comparison between iterative designs (head loss/system curves, velocity profiles, misc. design validation)

Mission Statement

Design and build a device capable of measuring:• Flow coefficients for the intake, exhaust, and

throttle valves at various open positions• Mass flow through the intake manifold and

exhaust ductwork.

Design Requirements

• Capacity 160 cfm @ 28 inH2O

• Repeatability +/- 5%

• Manufacturability In-house

• Cost $1,500

• Noise level < 95 dB

• Easy to use, maintain, and upgrade

Top Level Design

Design Analysis

• Finite Element Analysis

• Computational Fluid

Dynamics

• Numerical Analysis

Final Design and Prototype

Final Design and Prototype

DAQ and Control

Verification

• Noise level < 95 dB 92 dB

• Manufacturability In-house Yes

• Easy to use, maintain, and upgrade Yes

Verification

Verification

• Volume flow rate capacity 81 cfm @ 28 inH2O• Air box losses much higher than analysis predicts• Possibility of leakage Easy to modify/upgrade (modular design)

• Repeatability has not been verified Calibration equipment in transit

Conclusion

A complete prototype flow testing device has been designed and manufactured.

Further testing will be completed by VMS and Capstone team members.

Lessons learned• Engineering design process• Design for manufacturing• Teamwork• Time and budget constraints

Questions?