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P13222: FSAE Turbocharger Integration Kevin Ferraro, Phillip Vars, Aaron League Ian McCune, Brian Guenther, Tyler Peterson Slide 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 Slide 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 Slide 4 Customer Needs Review ImportanceDescriptionWas It Addressed? 5Overall Power and Torque Gains:Yes, verified with simulation, needs to be verified on dyno 5Optimized ECU Map for Best PerformanceOptimized with simulation, will be finalized on dyno 5Consistent Engine PerformanceWill be addressed with repeated dyno testing 5Necessary Engine Internals are Included with SystemYes-Carillo Rods and Swain Tech coated parts 4Adequate System CoolingYes-intercooler and radiator sized properly 4Sufficient Dyno Testing and ValidationWill be completed once fully assembled on dyno 4Optimized Turbo Size for ApplicationYes-Chosen using simulation results to avoid surge 4Meet FSAE Noise RegulationsWill be determined once dyno testing begins 3Quick Throttle ResponseSimulated, will be validated by dyno testing 3Easy to Access in CarYes-CAD shows this 3Compact Design in CarYes-CAD shows this 3Fit Within Constraints of Current ChassisYes-CAD shows this 2Easy to DriveWill be tested once on car 2Drivetrain Components Designed for Power Increase Yes, designers have used simulated values as design parameters 2Design for Intercooler Location (if required)Yes-CFD analysis confirms location is apt 1Readily Available Replacement PartsSome will have to be manufactured in house 1Simple Interface with Current EngineYes No modifications are required to interface 1Maximized Use of Composite MaterialYes-Plenum, intercooler parts Slide 5 Important Specifications FunctionSpecification Unit of Measure Ideal ValueComments/Status EnginePeak Power OutputHP and ft-lbf >= 60HP, 45 ft- lbf 62 HP Peak with 45 ft-lbf (GT-Power Model) IntakeMass Air Flowg/s>=40 58 g/s Peak (GT-Power Model) SystemOverall Weight Increaselbs