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Automotive Engineering Technology

Senior Design Project

COMPETITION

Objectives:

Abstract:

2012 Formula SAE Engine Team (Pictured from left to right front row):Gabriel Johnston, David Mengelkoch, Chris Langlois, Devin Moyer

(Back row): Tyler Saben, Ryan Maki, Steven Kruger, Bryce Tillman

Contact: (Bruce Jones) (507) 389-6383

The Formula SAE competition in Lincoln Nebraska offers 80 teams the challenge of designing, building and competing in a

formula style race car. The teams must create a final product that is compliant with the rules governing the competition and are

challenged to outperform competitors in various dynamic events, marketing, and design. The MSU 2012 FSAE engine team elected

to further improve last year’s KTM 525. The engine in previous years has been modified to run on E85, has been

converted to fuel injection had has been given a turbocharger. Changing airflow characteristics utilizing computational fluid

dynamic software, the team hopes to raise volumetric efficiencies and lower intake temperatures. The team will also experiment

with fuel injector placement seeking better fuel mixing and atomization. With the advantage of an extended design season, real

world testing will assist the 2012 team in succeeding where previous years have fallen short.

Pictured Above: Gabriel Johnston diagnosing the engine electrical sys-

tem on the Mustang Dyno with MoTech software.

Pictured Above: Bryce Tillman preparing the KTM 525 engine for the

SuperFlow dynamometer by installing the test plenum.

Pictured Above: Steve Kruger test driving the 2011 FSAE car at Da-

kota County Technical College. Pictured Above: Devin Moyer configuring the data acquisition system.

The purpose of which is to collect live data from dynamic vehicle testing.

- Engineer an intake system that flows 120 CFM through a

19mm restrictor and incorporates proper fuel injector placement

for ideal atomization.

- Manufacture an exhaust system which will provide proper con-

ditions for the turbocharger while allowing sufficient airflow and

holding sound levels under 110 decibels.

- Modify the valve train system for a turbocharged engine by al-

tering valve lift, overlap and event timing.

- Develop and implement an automatic shifting system to de-

crease acceleration time.

- Implement an effective data acquisition system to assist tuning

the FSAE car for maximum performance.

- Utilize the MoTec engine management system to fine tune the

engine and turbocharger operational characteristics.

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