Senior Design Final Project Presentation

Team FSAE Powertrain

Presented By: Michael Honeychuck, William Jay Kistler, Nick Piacente, Adam Stager
December 13th 2010

Supervisors
Team Sponsor:

Mr. Paul Schwarz

Mainline Porsche, Newtown Square, PA
Team Faculty Advisor:

Dr. Steve Timmins

University of Delaware, ME Department

General Project Info

To aid in the production of the powertrain for the 2010-11 SAE car to compete in the
annual FSAE competition next summer in California.

What is the Powertrain?

Constraints/Needs

Must spend less then $1000

Must adhere to all 2011 FSAE Competition Rules
Must complete objectives prior to semester end (December 17th)
Finish all dynamic events at FSAE competition

Overall Customer Wants

Minimize Weight
Maximize Durability/Reliability
Enhance Aesthetics/Neatness/Workmanship
Maximize Performance

Final Project Scope

As the SAE Powertrain Team, we are responsible for designing
and developing reliable support systems for the engine and
transmission on the 2010-11 UD SAE car.

The other main project goal was to develop detailed plans and
procedures for continued development within the UD SAE club.
Our project was divided into 3 subsystems:
1. Drivetrain
2. Air System
3. Engine Cooling

Final Project Deliverables

Drivetrain
Limited slip differential with custom

housing and mounting

2 rear axles
2 rear hubs
2 aluminum axle/hub spacers

Air System
Prototype air intake
Prototype exhaust

Engine Cooling
radiator
electric pull fan
Plans for radiator/fan duct work

Final Product Overview

Project Aspect 1: Drivetrain

Transfer engines torque

through differential, axles,

and hubs, to drive wheels

Differential: Final Product

Purchased Honda TRX ATV

limited slip differential

Used stock geometry and

mounting locations
Manufactured aluminum

carrier, uprights,
connectors, adapters

Differential: Exploded View

1.
2.
3.
4.
5.
6.

Honda TRX Limited Slip Differential

Differential Housing
Housing O-ring Seals
Drain Bolt and Seal
Hardware Seals
Hardware
8

12
11

12

7 9

11

9 7
3

7. Press Fit Adapter

8. Sprocket
9. Bearing
10. Upright Connections
11. Axle Seals
12. Uprights

10

3
3

Differential: Validation of Metrics

Method

Target
Metric

Old

New

Savings

Cost

---

<$600

$628

$534

$94.00
(14%)

Weight

Scale

<7 lbs

7.75 lbs

6.10 lbs

1.65 lbs
(21%)

Total Assembly
Length

Calipers

Durability

Evaluation

<10 inches 10.25 inches 4.96 inches

No
Leakage

present

not fully
tested

5.29 inches
(51%)

---

Differential: Testing and Validation

Upright Stress Test
(Bearing Seize)
17,700.4
14,225.4
13,275.3
10,325.3
8,850.2
7,375.2
5,900.2
2,950.1
0.1

Factor of Safety
Greater than two

Initial Filling and Spin Test

-More than 25% of total internal
volume filled
-Spun for 50 turns

Differential: Path Forward

Final testing will take place during

Winter Session 2011

Mimic conditions of 45-minute

endurance event
Check for oil leakage
a: Application specific seals

b: O-ring face seals

c: Press fits

Rear Axles: Final Product

(2) 18Honda TRX ATV axles

(Purchased)

Axles cut, 4130 Steel extensions added

for length

ATV axles press fit into extension

using an acetylene torch for thermal
expansion

Welded at four points over the press

fits of each axle

Rear Axles: Testing and Validation

Manufacture four test

axles, and testing

apparatus
Apparatus fixed to

platform in the Instron

machine in Spencer
Laboratory, tension
force applies to wire
rope, which creates a
moment through the
lever arm to the test
main shaft

Rear Axles: Testing and Validation

Find maximum allowable torque input, failure

mode
Torque before failure: 335 ft-lbs (target 168 ft-

lbs)
Failure Point press fit and weld points axle

shaft slips relative to the extension

Rear Axles: Validation of Metrics

Old

New (Left
Axle

New
(Right
Axle)

Savings

<$1,000
as a team

$1775.60

$122.47

$122.47

$1,530.66

Weight

6.9 lbs

6.9lbs

6.3

6.9 lbs

0.6lbs

Deflection @ 20
ft-lbs

Less than
1 degree

0.68
degrees

0.61
degrees

0.82
degrees

Insignificant

Allowable Static
Torque

168 ft-lbs

---

335 ft-lbs

335 ft-lbs

---

Target
Metric
Cost

Rear Axles: Path Forward

Can be permanently pressed into differential and rear hubs

once hubs are completed

Rear Hubs: Geometric Constraints

Hubs: Final Product

(2) Machined and

welded 4130 steel

hubs, 3 part
assembly
(2) Machined

aluminum wheel
guides
(2) Purchased Taylor

Racing Products
64mm wheel
bearings
Hardware

Rear Hubs: Validation

FEA Simulation
Static Stress Tests:

Factor of Safety

Resting

Acceleration

Braking Mode 1

Braking Mode 2

Cornering

19.4

5.83

7.37

2.78

2.64

Fatigue Tests:
Braking Mode 2 Failure after 33hrs
Cornering Failure after 28hrs
Cost Minimized: $130 (after splining and heat treating)
Weight Minimized: 3.1lb each

Rear Hubs: Path Forward

Have hubs heat-treated and broached (internally splined) at

RCV Performance over Winter Session 2011

Press lug bolts and wheel bearings in place
Complete upright assemblies

with components from

suspension
Install on car and observe performance

Project Aspect 2: Air System

Allows engine to breath via

air intake and exhaust

Intake must include 20mm

restrictor to limit power

Intake must be inside blue

pyramid

Exhaust must maintain

engine noise <110dB

Air Intake: Final Product

(1) Prototype air intake with adjustable plenum and runner tube
Engine Mount
Flange
Throttle Body With
Throttle Actuator and
Position Sensor

Fuel Injector
Mount

Mass Air Flow

Sensor Port

Double Conical
Air Filter

Expandable
Runner

Mandatory 20mm
Restrictor
Velocity Stack

Expandable
Plenum

Air Intake: Validation

09-10 Car

New Prototype

Air Filtration Area

17.69in2

43.24in2

Plenum Volume

2.5*511cc

[2.5*511cc:5*511cc]

Runner Length

13.3in

[11.3in:17.3in]

Post Restrictor Component Order

Fuel Injector Position

Minimized Cost: $110

Air Intake: Path Forward

Utilize adjustable intake for tuning/performance tests on

dyno during winter session 2011 examining Horsepower and

Torque versus RPM to find optimum plenum volume and
runner length.
Use CFD software to optimize design
Manufacture final air intake
Install on car and observe performance

Exhaust: Final Product

Expandable Exhaust

Prototype
Stainless Steel Expandable
Main Tube (1-5/8 OD)
Expandable from 27 35
(Total Exhaust Length)
Uses copper insulating
wrap to reduce heat in the
engine bay.
FMF Q4 muffler

Exhaust: Final Product

Noise Function of airflow

out of exhaust valve,

length of primary tube,
outer diameter and
thickness of the tube,
number of bends, size and
efficiency of the muffler
All materials for prototype

were given from FSAE

Exhaust: Future Testing and Validation

Noise Test:
Test for exhaust
noise following the
guidelines of the
FSAE noise test, at
optimal air intake
size and proper
engine tuning
Noise readings
taken in decibels at
10,500 RPM
110 dB constraint

Previous Exhaust 28

primary length, passed

noise test last year at
competition
Expandable Exhaust

27 35 primary
length
Compromise between

noise and power based

on length of primary
tube

Exhaust: Path Forward

Increase muffler sound dampening qualities - repack muffler

gauze
Perform noise tests at varying main tube lengths once the

final air intake is manufactured and the engine is properly

tuned

Project Aspect 3: Cooling

Must use plain

water as engine
coolant

Engine Cooling: Final Product

2004-05 Yamaha YFZ450

radiator
Derale Cooling Products 7

Tornado Push/Pull Fan

4 feet of 1 OD rubber heater

hose
Pressure relief valve on

engine
Radiator bolted to right side

of chassis

Engine Cooling: Testing

2009-10 car

Inlet Port

Let car reach operating

temperature
Inlet/outlet temperature

readings were taken from

radiator
Readings taken at idle (3,500

RPM), half throttle (6,500

RPM), and full throttle (10,500
RPM)
Performed with 2009-10
electric fan 0.375 inches behind
radiator

Outlet Port

Engine Cooling: Validation of Metrics

Target Metric

Old System New System

Savings

Cost

<$15

---

$9

---

Total Weight

<5 lbs

4.75 lbs

4.25 lbs

0.5 lbs (12%)

Volume Space

< 1,872 cubic inches

(8x13x18)

500 cubic
inches
(10x10x5)

1,465 cubic
inches
(7.4x11x18)

none

Heat Dissipated

>17,000 W

16,861 W

20,753 W

3,892 W (23%)

Fan Amperage Draw

<5 A

---

4.8A

---

Engine Cooling: Path Forward

Detailed ducting designs are available for composite material

manufacturing over Winter Session 2011

Special Thanks
We would like to give a special thanks to the following people
and businesses:
Ernie Martelli, Martellis Metal FabricationIvyland, PA

Adam Kinzey and Doug Brunner UD fuel cell laboratory

Steve BeardUD ME student machine shop
PowerSports EastBear, DE
RCV PerformanceLoves Park, IL
CMXIvyland, PA
Dale Cherry, Injection ConnectionHorsham, PA

Thank you for attending

our presentation. What
questions can we answer?

Applicable 2011 FSAE Rules

Must use a 4-stroke engine, up to 610 cc piston displacement
Air intake must lie within space defined by top roll hoop and

outside edges of tires

A maximum 20-mm restrictor must be placed inside air

intake between throttle and engine

Must use water as engine coolant
Exhaust components must be less than 45 cm behind rear

axles and less than 60 cm above the ground

Maximum permitted exhaust level is 110 dB

Starting Point: 2009-10 UD SAE Car

Single Cylinder, 511-cc

Yamaha YFZ450 ATV

engine, rear mounted,
chain drive
High Power-to-Weight

Ratio