Browse Topic: Racing engines

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SAE TOMORROW TODAY: Going Turbo with McLaren: The Engine Company1293002/12/2021
The Delorean. The Diamondback Viper. The Pontiac Grand Prix Turbo. McLaren has had a long rich history, engineering and building engines that have raced through history. We spoke with Wiley R. McCoy, Retired CEO, Technical Advisor to McLaren Engineering and Roger S. Meiners, Technical Advisor and Author of McLaren: The Engine Company, to discuss how the legacy of McLaren engineering and racing lives on. Racing requires perfection. Discover how the precision, process, hardwork and discipline of developing and creating McLaren's turbo-charged racing engines attracted manufacturers and influenced the production industry and hear first-hand what it was like to work on some of the world's most impressive automotive marvels from the people who worked on them. Discover the legacy. Read McLaren: The Engine Company to explore the rich history and lasting impact of this iconic brand.
Hineman, Marcie
Initial Investigations into the Benefits and Challenges of Eliminating Port Overlap in Wankel Rotary Engines2020-01-028004/14/2020
The Wankel rotary engine historically found limited success in automotive applications due in part to poor combustion efficiency and challenges around emissions. This is despite its significant advantages in terms of power density, compactness, vibrationless operation, and reduced parts count in relation to the 4-stroke reciprocating engine, which is now-dominant in the automotive market. A large part of the reason for the poor fuel economy and high hydrocarbon emissions of the Wankel engine is that there is a very significant amount of overlap when the ports are opened and/or closed by the rotor apices (so-called peripheral ports). This paper investigates the benefits of zero overlap from a production engine with this characteristic and the effect of configuring a peripherally-ported Wankel engine in such a manner. As discussed in the paper, arranging this condition for peripherally-ported engines unfortunately reduces the trapped compression and/or expansion ratios significantly
Turner, James, Turner, Matthew, Vorraro, Giovanni, Thomas, Toby
McLaren: The Engine CompanyR-48503/13/2020
McLaren: The Engine Company is the previously untold story of McLaren Engines, an American company founded in 1969 by Bruce McLaren and his partners to build engines for McLaren's legendary Can-Am and Indy Cars. From this base in suburban Detroit were born the mighty big-block Chevrolet V8s that powered the iconic orange cars to two of their five consecutive Cam-Am championships. McLaren's busy dyno rooms also spawned the howling turbo Offenhausers that put Mark Donohue and Johnny Rutherford in Victory Lane at Indianapolis three times between 1972 and 1976. For decades this non-descript shop was the hotbed of horsepower for factories and top independents alike. McLaren Engines developed the turbocharged Cosworth DFV Formula 1 engine that powered Indy cars for both Team McLaren and Penske Racing. It rendered BMW's turbo engine for U.S. IMSA racing that later became BMW's Formula 1 weapon. The long list of race engines developed here powered Buick Indy and IMSA cars, BMW GTP cars
Meiners, Roger
Developing High-Performance Motorcycle Oils2019-32-050501/24/2020
Published motorcycle lubricant research often focuses on developments to meet certain specifications, regulatory requirements, or a combination of the two. Seemingly missing from the literature is research where the primary goal is development of a lubricant that enables maximum torque, power and acceleration from a machine for the purpose of winning races. The present study combines the two areas of research, where a high-performance motorcycle engine oil platform is developed to be used in competition, while simultaneously meeting the necessary regulations and specifications to be useful for commuters and leisure riders alike. Well-known are the demands on a motorcycle oil, which must lubricate and protect the crankcase, clutch and gears, all of which have competing requirements such that a strategy to improve the performance in one area can cause a detriment in another. Formulating for racing engines that are typically much more powerful than production versions further exacerbates
Marcella, Mike, Johnson, Aaron
Using RON Synergistic Effects to Formulate Fuels for Better Fuel Economy and Lower CO2 Emissions2019-01-215512/19/2019
The knock resistance of gasoline is a key factor to decrease the specific fuel consumption and CO2 emissions of modern turbocharged spark ignition engines. For this purpose, high RON and octane sensitivity (S) are needed. This study shows a relevant synergistic effect on RON and S when formulating a fuel with isooctane, cyclopentane and aromatics, the mixtures reaching RON levels well beyond the ones of individual components. The same is observed when measuring their knock resistance on a boosted single cylinder engine. The mixtures were also characterized on a rapid compression machine at 700 K and 850 K, a shock tube at 1000 K, an instrumented and an adapted CFR engine. The components responsible for the synergistic effects are thus identified. Furthermore, the correlations plotted between these experiments results disclose our current understanding on the origin of these synergistic effects. This study concludes that this synergistic effect encourages formulating highly paraffinic
Dauphin, Roland, Obiols, Jerome, Serrano, David, Fenard, Yann, Comandini, Andrea, Starck, Laurie, Vanhove, Guillaume, Chaumeix, Nabiha
Using RON Synergistic Effects to Formulate Fuels for Better Fuel Economy and Lower CO2 Emissions2019-01-2155-TEST-REC12/19/2019
The knock resistance of gasoline is a key factor to decrease the specific fuel consumption and CO2 emissions of modern turbocharged spark ignition engines. For this purpose, high RON and octane sensitivity (S) are needed. This study shows a relevant synergistic effect on RON and S when formulating a fuel with isooctane, cyclopentane and aromatics, the mixtures reaching RON levels well beyond the ones of individual components. The same is observed when measuring their knock resistance on a boosted single cylinder engine. The mixtures were also characterized on a rapid compression machine at 700 K and 850 K, a shock tube at 1000 K, an instrumented and an adapted CFR engine. The components responsible for the synergistic effects are thus identified. Furthermore, the correlations plotted between these experiments results disclose our current understanding on the origin of these synergistic effects. This study concludes that this synergistic effect encourages formulating highly paraffinic
Dauphin, Roland, Obiols, Jerome, Serrano, David, Fenard, Yann, Comandini, Andrea, Starck, Laurie, Vanhove, Guillaume, Chaumeix, Nabiha
Virtual Investigation of Real Fuels by Means of 3D-CFD Engine Simulations2019-24-009009/09/2019
The reduction of both harmful emissions (CO, HC, NOx, etc.) and gases responsible for greenhouse effects (especially CO2) are mandatory aspects to be considered in the development process of any kind of propulsion concept. Focusing on ICEs, the main development topics are today not only the reduction of harmful emissions, increase of thermodynamic efficiency, etc. but also the decarbonization of fuels which offers the highest potential for the reduction of CO2 emissions. Accordingly, the development of future ICEs will be closely linked to the development of CO2 neutral fuels (e.g. biofuels and e-fuels) as they will be part of a common development process. This implies an increase in development complexity, which needs the support of engine simulations. In this work, the virtual modeling of real fuel behavior is addressed to improve current simulation capabilities in studying how a specific composition can affect the engine performance. The goal is to create a series of models that
Cupo, Francesco, Chiodi, Marco, Bargende, Michael, Koch, Daniel, Wachtmeister, Georg, Wichelhaus, Donatus
Intake Manifold Primary Trumpet Tuning Options for Fuel Flow Limited High Performance I.C.E.2019-24-000509/09/2019
The 2014 change in Formula One regulations, from naturally aspirated to highly-downsized and heavily-boosted hybridized power units, led to a relevant increase of the internal combustion engine brake specific power output in comparison with former V-8 units. The newly designed “down-sized” engines are characterized by a fuel flow limitation and a relevant increase in the thermal loads acting on the engine components, in particular on those facing the combustion chamber. Furthermore, efficiency becomes an equivalent paradigm as performance. In the power unit layout, the air path is defined by the compressor, the intercooler and the piping from the intake plenum to the cylinder. Intake duct length is defined from intake plenum to valve seat and it is a key parameter for engine performance. In order to find the optimum length different design criteria can be applied: the so called “tuning”, the “un-tuning” or the “anti-tuning” are all valid possibilities, showing pros and cons. The scope
Rosetti, Angelo, Iotti, Corrado, Cantore, Giuseppe
A Review of Spark-Assisted Compression Ignition (SACI) Research in the Context of Realizing Production Control Strategies2019-24-002709/09/2019
This paper seeks to identify key input parameters needed to achieve a production-viable control strategy for spark-assisted compression ignition (SACI) engines. SACI is a combustion strategy that uses a spark plug to initiate a deflagration flame that generates sufficient ignition energy to trigger autoignition in the remaining charge. The flame propagation phase limits the rate of cylinder pressure rise, while autoignition rapidly completes combustion. High dilution within the autoignited charge is generally required to maintain reaction rates feasible for production. However, this high dilution may not be reliably ignited by the spark plug. These competing constraints demand novel mixture preparation strategies for SACI to be feasible in production. SACI with charge stratification has demonstrated sufficiently stable flame propagation to reliably trigger autoignition across much of the engine operating map. A key controls challenge of SACI is the two regimes of combustion are near
Robertson, Dennis, Prucka, Robert
A New Approach for Development of a High-Performance Intake Manifold for a Single-Cylinder Engine Used in Formula SAE Application03-12-04-002707/26/2019
The Formula SAE (FSAE) is an international engineering competition where a Formula style race car is designed and built by students from worldwide universities. According to FSAE regulation, an air restrictor with circular cross section of 20 mm for gasoline-fuelled and 19 mm for E-85-fuelled vehicles is to be incorporated between the throttle valve and engine inlet. The sole purpose of this regulation is to limit the airflow to the engine used. The only sequence allowed is throttle valve, restrictor and engine inlet. A new approach of combining Ram theory and acoustic theory methods are investigated to increase the performance of the engine by designing an optimized intake runner for a particular engine speed range and an optimized plenum volume in this range. Engine performance characteristics such as brake power, brake torque and volumetric efficiency are taken into considerations. Ricardo WAVE simulation software is used to evaluate the impacts of plenum volume and runner length on
Venugopal, Thangavel, Anubhav, Routray
High Power-Density, High Efficiency, Mechanically Assisted, Turbocharged Direct-Injection Jet-Ignition Engines for Unmanned Aerial Vehicles01-12-01-000205/02/2019
More than a decade ago, we proposed combined use of direct injection (DI) and jet ignition (JI) to produce high efficiency, high power-density, positive-ignition (PI), lean burn stratified, internal combustion engines (ICEs). Adopting this concept, the latest FIA (Fédération Internationale de l’Automobile) F1 engines, which are electrically assisted, turbocharged, directly injected, jet ignited, gasoline engines and work lean stratified in a highly boosted environment, have delivered peak power fuel conversion efficiencies well above 46%, with specific power densities more than 340 kW/liter. The concept, further evolved, is here presented for unmanned aerial vehicle (UAV) applications. Results of simulations for a new DI JI ICE with rotary valve, being super-turbocharged and having gasoline or methanol as working fuel, show the opportunity to achieve even larger power densities, up to 430 kW/liter, while delivering a near-constant torque and, consequently, a nearly linear power curve
Boretti, Alberto
Investigation of an Innovative Combustion Process for High-Performance Engines and Its Impact on Emissions2019-01-003901/15/2019
Over the past years, the question as to what may be the powertrain of the future has become ever more apparent. Aiming to improve upon a given technology, the internal combustion engine still offers a number of development paths in order to maintain its position in public and private mobility. In this study, an innovative combustion process is investigated with the goal to further approximate the ideal Otto cycle. Thus far, similar approaches such as Homogeneous Charge Compression Ignition (HCCI) shared the same objective yet were unable to be operated under high load conditions. Highly increased control efforts and excessive mechanical stress on the components are but a few examples of the drawbacks associated with HCCI. The approach employed in this work is the so-called Spark Assisted Compression Ignition (SACI) in combination with a pre-chamber spark plug, enabling short combustion durations even at high dilution levels. This operation mode leads to substantial improvements in
Koch, Daniel, Berger, Vinicius, Bittel, Alexander, Gschwandtner, Maximilian, Wachtmeister, Georg, Chiodi, Marco, Kaechele, Andreas, Bargende, Michael, Wichelhaus, Donatus
Progress of Direct Injection and Jet Ignition in Throttle-Controlled Engines2019-26-004501/09/2019
Direct injection and jet ignition is becoming popular in electrically assisted, turbocharged, F1 engines because of the pressure to reduce fuel consumption. Operation from homogeneous stoichiometric up to lean of stoichiometry stratified about λ = 1.5, occurs with fast combustion of reduced cyclic variability thanks to the enhanced ignition by multiple jets of hot, partially reacting products travelling through the combustion chamber. The fuel consumption has thus been drastically reduced in an engine that is, however, still mostly throttle controlled. The aim of the present paper is to show the advantages of direct injection and jet ignition based on model simulations of the operation of a high-performance throttle-controlled engine featuring rotary valves.
Boretti, Alberto
Performance Improvements to a Production, Semi Direct Fuel Injected, 2-Stroke Engine for a Racing Application2018-32-004310/30/2018
The following material presents an overview of using a production 2-stroke engine and transforming it into one for the racing application of Snocross. This paper will explore the changing of engine hardware, engine related hardware and software while staying within the project scope for schedule, tooling capabilities and rules of the governing body for Snocross racing. This conversion process is discussed in detail through analytical calculations, to the experimental validation with dynamometer and airflow bench data.
Olson, Andy, Hayes, Ryan
Model-Based Approach for Engine Performance Optimization2018-32-008210/30/2018
State-of-the-art motorcycle engines consist of numerous variable components and require a powerful motor management to meet the growing customer expectations and the legislative requirements (e.g. exhaust and noise emissions, fuel consumption) at the same time. These demands are often competing and raise the level of complexity in calibration. In the racing domain, the optimization requirements are usually higher and test efficiency is crucial. Whilst the number of variables to control is growing, the time to perform an engine optimization remains the same or is even shortened. Therefore, simulation is becoming an essential part of the engine calibration optimization. Considering the special circumstances in racing, involving valuable hardware, as well as extremely short development and calibration iteration loops, only transient testing is possible. By utilizing model-based testing and optimization, Ducati Corse, the racing team division of the well-known motorcycle manufacturer
Bartoccini, Davide, Niedermaier, Peter, Grassberger, Helmut Peter
Methodical Selection of Sustainable Fuels for High Performance Racing Engines2018-01-174909/10/2018
As the importance of sustainability increases and dominates the powertrain development within the automotive sector, this issue has to be addressed in motorsports as well. The development of sustainable high-performance fuels defined for the use in motorsports offers technical and environmental potential with the possibility to increase the sustainability of motorsports at the same or even a better performance level. At the moment race cars are predominantly powered by fossil fuels. However due to the emerging shift regarding the focus of the regulations towards high efficient powertrains during the last years the further development of the used fuels gained in importance. Moreover during the last decades a huge variety of sustainable fuels emerged that offer a range of different characteristics and that are produced based on waste materials or carbon dioxide. This study investigates the question of which sustainable fuels offer the characteristics suitable for high-performance race
Schwarz, Lea, Bargende, Michael, Dreyer, Stefan, Baretzky, Ulrich, Kotauschek, Wolfgang, Wohlgemuth, Sebastian, Bach, Florian
Virtual Optimization of Race Engines Through an Extended Quasi Steady State Lap Time Simulation Approach2018-01-058704/03/2018
Minimizing the lap time for a given race track is the main target in racecar development. In order to achieve the highest possible performance of the vehicle configuration the mutual interaction at the level of assemblies and components requires a balance between the advantages and disadvantages for each design decision. Especially the major shift in the focus of racecar powerunit development to high efficiency powertrains is driving a development of lean boosted and rightsized engines. In terms of dynamic engine behavior the time delay from requested to provided torque could influence the lap time performance. Therefore, solely maximizing the full load behavior objective is insufficient to achieve minimal lap time. By means of continuous predictive virtual methods throughout the whole development process, the influence on lap time by dynamic power lags, e.g. caused by the boost system, can be recognized efficiently even in the early concept phase. As a first step, this paper presents
Malcher, Simon, Bargende, Michael, Grill, Michael, Baretzky, Ulrich, Diel, Hartmut, Wohlgemuth, Sebastian
Improvement of Formula Student Racecar Performance with Rotary Variable Runner Length for the Intake System2018-01-097704/03/2018
The purpose of this research is to implement the variable intake manifold on a Formula Student racecar to achieve a lower overall Autocross lap time. A previous version of the linearly adjustable variable intake manifold prototype was able to deliver an improved engine performance in the form of wider range of engine RPM with high torque, but its dimension did not conform to the FSAE regulation. This research focuses on developing a physically compact rotary variable intake system to achieve a favorable characteristic while conforming to the FSAE rules. The engine is expected to perform better than the previous one by comparing the range of engine RPM which produces torque greater than 48.47 N-m, representing 90% of maximum torque or our 2015 car with a conventional intake system. The optimum runner length is determined using the pressure wave tuning method. CFD analysis is performed to determine the inlet-plenum diameter ratio to ensure uniform mass flow distributions among four
Chantharasenawong, Chawin, Chanta, Alongkorn, Siripongarpone, Pongsiri, Kaoudom, Supawit
Ion Current Measurement of Diluted Combustion Using a Multi-Electrode Spark Plug2018-01-113404/03/2018
Close-loop feedback combustion control is essential for improving the internal combustion engines to meet the rigorous fuel efficiency demands and emission legislations. A vital part is the combustion sensing technology that diagnoses in-cylinder combustion information promptly, such as using cylinder pressure sensor and ion current measurement. The promptness and fidelity of the diagnostic are particularly important to the potential success of using intra-cycle control for abnormal cycles such as super knocking and misfiring. Many research studies have demonstrated the use of ion-current sensing as feedback signal to control the spark ignition gasoline engines, with the spark gap shared for both ignition and ion-current detection. During the spark glow phase, the sparking current may affect the combustion ion current signal. Moreover, the electrode gap size is optimized for sparking rather than measurement of ion current. For improving fuel efficiency using diluted combustion, the ion
Dev, Shouvik, Sandhu, Navjot Singh, Ives, Mark, Yu, Shui, Zheng, Ming, Tjong, Jimi
Model-Based Control of Test Bench Conditioning Systems2018-01-012904/03/2018
Engine test benches are crucial instruments to perform tests on internal combustion engines. Since many factors affect tests results, an engine test bench is usually equipped with several conditioning systems (oil, water and air temperature, air humidity, etc.), in order to maintain the controlled variables to the target values, throughout the test duration. The conditioning systems are often independently controlled by means of dedicated programmable logic controllers (PLC), but a centralized model-based management approach could offer several advantages in terms of promptness and accuracy. This work presents the application of such control methodology to oil, water, and HVAC (heating, ventilating, and air conditioning) conditioning systems, where each actuator is managed coupling model-based open loop controls to closed loop actions. The main advantage of integrating the management of several actuators is that the control actions can be coordinated, similarly to what has been
Corti, Enrico, Taccioli, Michele, Ponti, Fabrizio
A Study Isolating the Effect of Bore-to-Stroke Ratio on Gasoline Engine Combustion Chamber Development2016-01-217710/17/2016
A unique single cylinder engine was used to assess engine performance and combustion characteristics at three different strokes, with all other variables held constant. The engine utilized a production four-valve, pentroof cylinder head with an 86mm bore. The stock piston was used, and a variable deck height design allowed three crankshafts with strokes of 86, 98, and 115mm to be tested. The compression ratio was also held constant. The engine was run with a controlled boost-to-backpressure ratio to simulate turbocharged operation, and the valve events were optimized for each operating condition using intake and exhaust cam phasers. EGR rates were swept from zero to twenty percent under low and high speed conditions, at MBT and maximum retard ignition timings. The increased stroke engines demonstrated efficiency gains under all operating conditions, as well as measurably reduced 10-to-90 percent burn durations. The results were quite non-linear, with the majority of the gains achieved
Hoag, Kevin L., Mangold, Barrett, Alger, Terrence, Abidin, Zainal, Wray, Christopher, Walls, Mark, Chadwell, Christopher
A 24-hour battle of speed and EFFICIENCY16AUTP06_0106/01/2016
At Le Mans this month, amped-up hybrid prototypes from Audi and Toyota face a revamped Porsche 919 while Ford hopes to recapture glory with its new GT-R. World endurance racing at Le Mans is no longer only about who finishes first after a grueling 24 hours, but also about winning with the greatest energy efficiency. For 2016, the Federation Internationale de L'Automobile (FIA) has tightened the fuel allowance for the top-echelon Le Mans Prototype 1 (LMP1) category in an attempt to further link racing and efficiency-and as an attempt to arrest the stunning increases in speed seen during 2015. This year, the fuel allowed per lap has been reduced by 10%, for an approximate reduction in energy per lap of about 10 megajoules (2.77 kW·h). Peak instantaneous fuel flow also is reduced by 10%.
Carney, Dan
Pushing the ICE forward, gradually16AUTP06_0206/01/2016
Emergent technologies from BorgWarner, Eaton and Mahle aim for greater efficiency in gasoline and diesel engines. Free lunches don't exist in the quest to improve vehicle efficiency and reduce emissions. No one knows this better than powertrain engineers whose work is a constant series of tradeoffs that must be tackled if the auto industry is serious about reducing CO2. Do you want enhanced drive-cycle fuel economy? It could cost you real-world performance. You say your latest dyno tests indicate efficiency improvements through charge dilution? Well, what about the impact to specific power and torque and full-load pumping losses? These are the arcane kinds of tradeoffs the industry grapples with as it seeks effective, low-cost production engine solutions, noted Dr. Terry Alger, who directs spark-ignition R&D at the Southwest Research Institute (SwRI).
Brooke, Lindsay
Port Design Criteria for 2-Stroke Loop Scavenged Engines2016-01-061004/05/2016
Interest in 2-stroke engines has been recently renewed by several prototypes, developed for the automotive and/or the aircraft field. Loop scavenging, with piston controlled ports is particularly attractive, but the configurations successfully developed in the past for motorbike racing (in particular, the 125cc unit displacement, crankcase pump engines), are not suitable for automotive applications. Therefore, new criteria are necessary to address the scavenging system design of the new generation of 2-stroke automobile/aircraft engines. The paper reviews the transfer ports optimization of a loop scavenged 2-stroke cylinder, whose main parameters were defined in a previous study. The optimization has been carried by means of a parametric grid, considering 3 parameters (2 tilt angles, and the focus distance), and 3 different engine speeds (2000-3000-4000 rpm, assuming a Diesel engine). A set of scavenging CFD-3d simulations have been performed by using a customized version of KIVA-3V
Mattarelli, Enrico, Rinaldini, Carlo Alberto, Savioli, Tommaso
Transient Gas Exchange Simulation and Uniflow Scavenging Analysis for a Unique Opposed Piston Diesel Engine2016-01-108704/05/2016
To achieve more stringent exhaust emission regulations will face more and more daunting challenges nowadays. It needs more new technologies to improve the IC engine performance but needing higher costs in order to meet Euro 6 and EPA standards in USA. Recently the opposed-piston engine (OPE) has been treated as the promising product to meet these new regulations but relatively lower costing. Although two-stroke OPE owning inherent thermal efficiency and power density advantages, the inefficient scavenge efficiency appears to become the main obstacle to enhance combustion efficiency whilst reducing exhaust gas emission. For the improvement of scavenge efficiency the transient gas exchange simulation was carried out for multiple Cases here, including two intake port configurations at various back pressures in exhaust system and two port timings. The effects of exhausting back pressure, porting timing and intake port layout on scavenging and trapped air mass in cylinder all were
Changming, He, Sichuan, Xu
Technology Choices for Optimizing the Performance of Racing Vehicles2016-01-117304/05/2016
In the continuous search for technology to improve the fuel economy and reduce greenhouse gas emission levels from the automotive vehicle, the automotive industry has been evaluating various technological options. Since the introduction of stringent legislative targets in Europe as well as in the United States of America in late 20th Century, one of the viable options identified by the industry was the application of alternative powertrain. On the motorsport arena, changes introduced by the Formula 1 governing body (FIA) for the high-performance racing engines also focuses on fuel economy. FIA regulation for 2014 restricts the fuel-flow rate to a maximum of 100kg/hr beyond 10,500 rev/min and prescribe fuel flow rate below 10,500 rev/min operating conditions for the F1 Engines. In addition, Formula1 and Le Mans racing regulations actively promote the integration of the hybrid powertrain in order to achieve optimum fuel economy. Therefore, the aim of the present work is to evaluate
Bengolea, Federico, Samuel, Stephen
Performance of Ancillary Systems of 2014+ Le Mans LMP1-H Vehicles and Optimization2015-01-116304/14/2015
This study details the investigation into the hybridization of engine ancillary systems for 2014+ Le Mans LMP1-H vehicles. This was conducted in order to counteract the new strict fuel-limiting requirements governing the powertrain system employed in this type of vehicle. Dymola 1D vehicle simulation software was used to construct a rectilinear vehicle model with a map based 3.8L V8 engine and its associated ancillary systems, including oil pumps, water pump and fuel pump as well as a full kinetic energy recovery system (ERS). Appropriate validation strategy was implemented to validate the model. A validated model was used to study the difference in fuel consumption for the conventional ancillary drive off of the internal combustion engine in various situational tests and a hybrid-electric drive for driving engine ancillaries. Investigation showed that the implementation of hybrid ancillaries in the Le Mans circuit would achieve a 40cc fuel savings per lap over the conventional
Elias, Gabriel, Samuel, Stephen, Picarelli, Alessandro
A Study into Compression Ring Dynamics using Response Surface Methodology2015-01-133504/14/2015
For decades the operational dynamics of the compression ring during operation, have been subject to debate [1, 2, 3, 4, 5, 6, 7]. A complex computer simulation, using Design Of Experiments (DOE) methodology, was developed to study the effect of the compression ring rotation during running-in stages. Response Surface (RS) has been used to optimize ring displacement, as function of ring mass, width and radius. The optimised surface response has been compared to used compression rings and has shown a 2% variation between calculated and measured values.
Dickinson, Matthew W., Renevier, Nathalie, Calderbank, John
Development of a Third Generation Dynamic Intake Air Simulator for Single-Cylinder Test Engines2015-01-088504/14/2015
This paper details the development of a new dynamic Intake Air Simulator (IAS) for use on single-cylinder test engines, where the gas dynamics are controlled to accurately simulate those on a multi-cylinder engine during transient or steady-state operation. The third generation of Intake Air Simulators (IAS3) continues a development of new technology in the Powertrain Control Research Laboratory (PCRL) that replicates the multi-cylinder engine instantaneous intake gas dynamics on the single-cylinder engine, as well as the control of other boundary conditions. This is accomplished by exactly replicating the intake runner geometry between the plenum and the engine intake valve, and dynamically controlling the instantaneous plenum pressure feeding that runner, to replicate the instantaneous multi-cylinder engine intake flow. The plenum pressure is controlled in this technology by means of six rotary valves, seven proportional valves, and the throttle valve system from the representative
Murphy, Mark B., Moskwa, John J.
Demands on Future Timing drives - Chain and Belt in Competition2015-01-127504/14/2015
When designing a new internal combustion engine, the choice of technology for the timing drive system is one of the key decisions that determines the overall characteristics of the engine with far reaching implications on the remaining architecture and overall packaging of the engine. For Passenger car engines there are two mainstream technologies: toothed belts and chains. Each of these offers several sub-variants, such as dry vs. wet belt, or toothed vs. roller chain. This paper examines the differences between these technologies in relation to the key engine attributes including package, cost, weight, durability, NVH and frictional losses. A quantitative evaluation is made where possible, based on data collected from recent engine development programs, backed up by literature study and data from the component supply industry. These differences are reviewed in the light of current and expected future engine development trends in order to give a basis for the engine designer to choose
Schoeffmann, Wolfgang Johann, Truffinet, Caroline, Howlett, Michael, Ausserhofer, Norbert, Zurk, Andreas
A Study of a Highly Boosted and Efficient Downsized Ethanol Direct Injection (EDI) Engine in Two Different Configurations for the Purpose of Replacing High-Displacement Gasoline Engines2015-01-125504/14/2015
The paper presents a layout of a highly boosted Ethanol Direct Injected (EDI) engine with extreme downsizing, which represents a powerful means to reduce emissions at reduced production costs. The substitution of high-displacement engines (2.4- or 3.0-liter) by a downsized turbocharged EDI-engine is studied. The paper describes the detailed layout of all engine hardware and in particular, the cylinder head structure including the optimized intake and exhaust manifolds as well as implemented DI injectors. The paper continues with a presentation of the experimental data obtained at the engine test rig. The paper concludes presenting a series of experimental data obtained with the downsized engine mounted in a car as a replacement for its original high-displacement engine.
Pontoppidan, Michael, Baeta, Jose G. C.
Cumulated Microslip in Component Assembly of Engine and Gearbox2015-01-173704/14/2015
Today new automotive engine design is optimized in terms of mass. However, in terms of structural stiffness, optimizations mainly consider eigenfrequency criteria. But in assembly components with very low stiffness, cumulated microslip phenomena can occur when the structures are subject to cyclic loadings. In time and after a large number of cycles, macro-displacements can be observed between assembly components and then assembly failures will occur. Bush, plain bearing, roller bearing in conrod or in gearbox can be subject to this kind of problem. In this paper, after a short description of various mechanisms which can cause microreptation phenomena, two types of cumulated microslip occurring in the engine and the gearbox are presented. Behavior specificities will be highlighted to remind how unusual cumulated microslips are. Based on field data, it appears that the probability of both phenomena occurring is extremely low. This implies that it is not appropriate to use devices
Ligier, Jean-louis, Benoit, Mathieu, Damaz, Sylvain
A Naturally Aspirated Four Stroke Racing Engine with One Intake and One Exhaust Horizontal Rotary Valve per Cylinder and Central Direct Injection and Ignition by Spark or Jet2015-01-000603/10/2015
The paper discusses the benefits of a four stroke engine having one intake and one exhaust rotary valve. The rotary valve has a speed of rotation half the crankshaft and defines an open passage that may permit up to extremely sharp opening or closing and very large gas exchange areas. The dual rotary valve design is applied to a racing engine naturally aspirated V-four engine of 1000cc displacement, gasoline fuelled with central direct injection and spark ignition. The engine is then modeled by using a 1D engine & gas dynamics simulation software package to assess the potentials of the solution. The improved design produces much larger power densities than the version of the engines with traditional poppet valves revving at higher speeds, with reduced frictional losses, and with larger gas exchange areas while also improving the fuel conversion efficiency thanks to the sharpness of opening or closing events. The novelty in the proposed dual rotary valve system is the combustion chamber
Boretti, Alberto, Jiang, Shuheng, Scalzo, Joseph
Turbo/Supercharged Two/Four Stroke Engines with One Intake and One Exhaust Horizontal Rotary Valve per Cylinder and Central Direct Injection and Ignition2015-26-003101/14/2015
The present paper is an introduction to a novel rotary valve engine design addressing the major downfalls of past rotary valves applications while permitting the typical advantages of the rotary valves. Advantages of the solution are the nearly optimal gas exchange, mixture formation, ignition and combustion evolution thanks to the large gas exchange areas from the two horizontal valves per engine cylinder, the good shape of the combustion chamber, the opportunity to place a direct fuel injector and a spark or jet ignition device at the centre of the chamber. The novel engine design also permits higher speed of rotation not having reciprocating poppet valves and the reduced friction losses of the rotating only distribution. This translates in better volumetric efficiencies, combustion rates and brake mean effective pressures for improved power density and fuel efficiency. Additional advantages are the reduced weight and the better packaging. The paper proposes some CAD/CAE results but
Boretti, Alberto, Scalzo, Joseph
Piston Temperature Measurement in Internal Combustion with Telemetric Method2014-32-005111/11/2014
Currently, the improvement of fuel economy is the most important issue in automobile engine development. To improve fuel economy via greater thermal efficiency, the enhancement of the compression ratio and the reduction of thermal losses because of cooling have been widely investigated. These efforts to improve thermal efficiency increase the thermal load on pistons. Ensuring the reliability of the pistons and the antiknocking capacity of engines require a better understanding of piston temperature distributions through accurate measurements under various engine operating conditions. Thus, direct and indirect measurement methods have been developed to estimate the actual piston temperature. Direct methods, such as linkage-type measurements, are not typically applicable under higher engine speeds because of the poor durability of linkages. Indirect methods, such as material hardness-type measurements, can measure neither real-time piston temperature nor the temperature of piston skirts
Ishibashi, Akira, Nakamura, Muneaki, Muramatsu, Hitoshi
HAVE DIESEL WILL RACE (AND LEARN)14MOMP11_0111/01/2014
Mazda's factory SkyActiv diesel race program switched to the Prototype class in 2014, teaching the SpeedSource team valuable engineering lessons for 2015. FORMULA SAE STUDENT ENGINEERS, TAKE HEED: You're not alone in seeking technical solutions, facing setbacks, and often tiptoeing through the minefield of successful racecar development. There are pros in the same situation. Just ask Sylvain Tremblay, whose SpeedSource race team recently completed its first season in the Prototype class of the new TUDOR United Sports Car Championship Grand Am Series. “As the only diesel car running in Prototype, using a production-based engine and a new fuel, we're exploring new territory one race at a time,” said Tremblay, a veteran engineer and skilled race driver whose Florida-based engineering company has built and campaigned Mazda's U.S. “works” cars since the rotary-engine era.
Brooke, Lindsay
Cylinder Pressure Based Engine Calibration of a Formula SAE Racing Engine2014-36-035009/30/2014
Formula SAE racing engines must provide high output with maximum fuel efficiency despite the air restriction imposed by the rules. Throttle response and engine load control are very important due to the track characteristics with a few straights zones and many curves. In-cylinder pressure cyclic variations harm vehicle control and increase fuel consumption, due to the torque fluctuations. In order to reduce fuel consumption and improve vehicle drivability, engine calibration having the in-cylinder as a feedback parameter is an essential procedure and will be the focus of this paper. Test bench data with combustion analysis will be performed, using the COVIMEP as a combustion stability index. Tests were carried out on a motorcycle engine modified to run under the Formula SAE competition rules. A piezoelectric sensor was installed inside the combustion chamber to provide instantaneous pressure readings, which were used to on-line calculate the IMEP and perform a 200 cycle COVIMEP
Tatsch, Gabriel Azevedo, Martins, Mario Eduardo Santos, Lanzanova, Thompson, Sari, Rafael Lago, Taglieber, Victor Hugo, Görck, Cassio Lino
Sports cars embrace array of green technology14AUTP07_0207/01/2014
IMSA Tudor United SportsCar Championship promotes a variety of green technologies to link racing to the road. The International Motor Sports Association's Tudor United SportsCar Championship is the newly merged racing series for sports car racing in North America, ending the split between the American Le Mans Series and the Grand-Am racing series. One way the new series aims to boost interest in its racing and its cars is by strengthening the link between the cars on the track and those on the street. This gives manufacturers and fans alike more reason to be interested in the racing series.
Carney, Dan
A New Technique to Determine the Burning Velocity in a Gasoline Direct Injection Engine2014-01-117604/01/2014
Many approaches have been taken to determine the burning velocity in internal combustion engines. Experimentally, the burning velocity has been determined in optically accessible gasoline engines by tracking the propagation of the flame front from the spark plug to the end of the combustion chamber. These experiments are costly as they require special imaging techniques and major modifications in the engine structure. Another approach to determine the burning velocity is from 3D CFD simulation models. These models require basic information about the mechanisms of combustion which are not available for distillate fuels in addition to many assumptions that have to be made to determine the burning velocity. Such models take long periods of computational time for execution and have to be calibrated and validated through experimentation. This paper presents a new technique to determine the burning velocity in a production engine without making any modification in its structure, or use of
Mekhael, Shenouda, Estefanous, Fadi, Henein, Naeim, Zahdeh, Akram
A Novel Valve-Less Supercharged Small Two Stroke Engine of Top Brake Efficiency Above 36% and Power Density above 100 KW/Liter2013-01-277211/27/2013
The paper presents a novel design for a two stroke thermal engine that delivers excellent fuel economy and low emissions within the constraints of today's cost, weight and size. The engine features asymmetrical port timing through a novel translating and rotating piston mechanism. The engine is externally scavenged and supercharged, has wet sump and oil pressure lubrication, direct injection, it is lightweight, easy to build, with minimal number of parts, low production cost, ability to be balanced and compact design. The two stroke mechanism produces a linear motion of the pistons as well as an elliptical path on the surface of the cylinder. This allows the piston to sweep as well as travel past the ports. Suitable slots around the raised lip of the piston generate the asymmetry that makes the exhaust port to open first and to close first. The inlet port remains open to complete the cylinder charging and allow supercharging. Direct fuel injection is adopted for best results. The paper
Boretti, Alberto, scalzo, joseph
Improving the Fuel Economy of Supercharged Engine2013-32-911810/15/2013
The paper reviews the experimental development of fuel economy of engine powering the 2012 Formula SAE single seat race car of the University of Sophia. The balance of high power and low fuel consumption is biggest challenge of racing engine. It was found that improving the efficiency of engine by supercharging as a way to achieve that. In order to adapt the supercharger for the engine, the important design points are below: It was found that intake air blow-by gas at combustion chamber is increased in low engine speed. To improve that, the valve overlap angle was changed to adopt supercharged engine and improve effective compression ratio. Typically the racing engine demands maximum torque for performance but that does not imply that the air fuel ratio should be rich than theoretical. The point is the maximum torque of the engine is proportional to the amount of air intake. Therefore, supercharged engine is possible to increase the supercharging pressure for bigger torque. But the
Fukuhara, Yoshiki, Kimata, Naoya, Suzuki, Takashi
The Impact of Cellulosic Ethanol on the Performance and Emissions of a Circle Track Race Car2013-01-114904/08/2013
Ethanol has received both positive and negative attention as a renewable fuel for spark ignition engines. Studies of ethanol have shown improved volumetric efficiency, knock tolerance, and favorable burn curves[1]. Nevertheless, little research has been published exploring the impact of ethanol blends on race engine performance coupled with the impact on well-to-wheels (WTW) greenhouse gases, emissions, and petroleum reduction. In this work, a circle track race vehicle powered by a GM Performance Parts 6.2L OHV CT-525 engine was tested using 100 octane race fuel and E85 over a matrix of configurations. Carburetion vs. fuel injection configurations were benchmarked with both fuels, with the addition of 100- and 300-cells-per-inch catalytic convertors. Testing involved both dynamometer testing and on-track testing utilizing a portable emissions measurement system. These data were used to determine the WTW greenhouse gas reduction, petroleum displacement, and criteria emission reduction
Jehlik, Forrest, Bocci, Daniel
Analytical Comparison of a Turbocharged Conventional Diesel and a Naturally Aspirated Compact Compression Ignition Engine both Sized for a Highway Truck2013-01-173604/08/2013
The Compact Compression Ignition (CCI) engine concept was first described [1] in 1999. The design has since evolved with greater emphasis on high efficiency and a demonstration model is currently the subject of preliminary tests. This paper compares results of mechanical and thermodynamic simulations of two 450 kW engines. One is a conventional turbocharged six cylinder diesel engine and the other is a three module naturally aspirated CCI engine. The ubiquitous slider-crank mechanism that forms the basis of all current automotive engines has geometric limitations which are discussed as an introduction to the radically different CCI. According to the analysis, the CCI engine offers both higher efficiency and smaller size than the conventional engine. The reasons for the differences are described and quantified in the paper.
Clarke, John, O'Malley, Edward
Optimising Piston Ring Contact Face Chamfer for High Performance Engines2013-01-096504/08/2013
Internal combustion engine components have been a main research interest over many decades [1]. While bulk material and surface engineering developments have improved the resistance to fatigue, reduced the amount of wear and friction during operation, small improvements in race applications designs can increase the engine performance and give a competitive edge to racing engines. Piston rings are designed to create a seal which means that they will suffer large levels of material loss due to wear during operation. The compression ring is the top or closest ring to combustion gases and is exposed to the highest operating temperature. In this paper, the authors propose a design modification to the compression ring coated chamfer which can reduce stress concentration and material loss during operation.
Dickinson, Matthew W.
Valve Lift Profile Development and Optimization Using Matlab2013-01-172204/08/2013
The focus of this paper is the development and modelling of a reverse-poppet valve train assembly, placing a major emphasis on the optimization routine used to develop a short-duration camshaft profile. A user-programmable script, known as the penalty function, was written to assign weighted numeric values to certain parameters associated with the valve lift profile and its derivatives. These design parameters include maximum acceleration, peak lift, area under the lift curve and minimization of jerk. Optimization tools built into Matlab were then used to generate a profile which minimizes the overall ‘penalty’ associated with each parameter as it deviates from a user-defined ideal. A commercially available multi-body dynamics software package was used to evaluate the dynamic performance of the valve train incorporating the generated cam profile. A flexible-body spring element provided insight into spring surge and coil contact. Comparisons of the designed and simulated lift, velocity
Cameron, Iain, Minaker, Bruce
Optimized Air Intake for a Turbocharged Engine Taking into Account Water-Cooled Charge Air Cooler Reflective Properties for Acoustic Tuning2013-01-057504/08/2013
Unsteady intake wave dynamics have a first order influence on an engine's performance and fuel economy. There is an abundant literature particularly for naturally aspirated SI engines on the subject of intake manifolds and primary runner lengths aimed to achieve a tuned intake air line. A more demanding design for today's engines is to increase efficiency to meet the requirements of lower fuel consumption and CO2 emissions. Today's tendencies are downsizing the engine to meet these demands. And for drivability purposes, the engine is combined with a turbocharger coupled with a charge air cooler. However, when the engine's displacement is reduced, it will be very dependent on its boosting system. A particularly interesting point to address corresponds to the engine's operation in the low speed range and during transients where the engine has large pumping losses and poor boost pressure. This operation point can be optimized using acoustic supercharging techniques. The proposed solution
Mezher, Haitham, Migaud, Jerome, Raimbault, Vincent, Lelong, Jean-Gabriel, Chalet, David, Perrot, Nicolas, Hunault, Alexandre, Chesse, Pascal, Huurdeman, Bernhard
Directing diesel's debut in U.S. Grand-Am racing13MOMD0301_0203/01/2013
Speedsource's engineering director, a Formula SAE grad from the Univ. of Florida, is helping to put Mazda's new compounded-turbo diesel engine in the Grand-Am winner's circle. A FLORIDA-BASED ENGINEERING and racecar-development company is spearheading the debut of clean-diesel technology in U.S. Grand-Am road racing, with Formula SAE graduates leading the charge. SpeedSource Engineering has been Mazda's factory racecar development partner for nearly 20 years. This season the company is campaigning three all-new Mazda6-based sedans in Grand-Am's new GX class, which was created to encourage use of “clean” fuels and alternate propulsion systems. The 160-mph (257-km/h) racecars are powered by Mazda's new Skyactiv-D 2.2-L diesel, which will be an option on the 2014 production model. The stock-block race engine, modified to produce more than 400 hp (298 kW), is pioneering a new compounded-turbocharging system and a new synthetic clean diesel fuel. See story here: www.sae.org/mags/aei/11750.
Brooke, Lindsay
An Empirically Integrated CFD Method for Racing Engine Layout and Its Practical Demonstration2012-32-006810/23/2012
Racing engines are required to be developed quickly in order to adapt to ever-changing regulations. A CFD-based optimization would be a useful tool to discover the best solution given the restrictions of the regulations. However, a CFD approach requires repeated trials and errors until the best solution is found because the numerical goal is unknown and the specifications required for the goal are never calculated back when using CFD. Therefore, this paper proposes an Empirically Integrated CFD Method. It is a combination of a one-dimensional CFD and several empirical equations that are derived from the racing engine database with physical meanings. These empirical equations give the CFD-based optimization a proper goal and primary specifications so as to make the optimization loop converge rapidly. This method is experimentally verified for its practical application with a prototype engine. Moreover, this prototype engine reveals the impact of the combustion chamber design on the
Yasui, Shinsuke, Nakamura, Daisuke
Assessment of the Influence of Intake Duct Geometrical Parameters on the Tumble Motion Generation in a Small Gasoline Engine2012-32-009510/23/2012
During the last years the deep re-examination of the engine design for lowering engine emissions involved two-wheel vehicles too. The IC engine overall efficiency plays a fundamental role in determining final raw emissions. From this point of view, the optimization of the in-cylinder flow organization is mandatory. In detail, in SI engines the generation of a coherent tumble vortex having dimensions comparable to the engine stroke could be of primary importance to extend the engines' ignition limits toward the field of the dilute/lean mixtures. For motorbike and motor scooter applications, the optimization of the tumble generation is considered an effective way to improve the combustion system efficiency and to lower emissions, considering also that the two-wheels layout represents an obstacle in adopting the advanced post-treatment concepts designed for automotive applications. The aim of the paper is to use the 3D-CFD simulation tool to assess the intake duct geometry influence on
Falfari, Stefania, Brusiani, Federico, Bianchi, Gian Marco
KERS Braking for 2014 F1 Cars2012-01-180209/17/2012
Small, high power density turbocharged engines coupled to kinetic energy recovery systems are one of the key areas of development for both passenger and racing cars. In passenger cars, the KERS may reduce the amount of thermal energy needed to reaccelerate the car following a deceleration recovering part of the braking energy. This translates in a first, significant fuel energy saving. Also considering the KERS torque boost increasing the total torque available to accelerate the car, large engines working at very low brake mean effective pressures and efficiencies over driving cycles may also be replaced by small higher power density engines working at much higher brake mean effective pressures and therefore much higher part load efficiencies. In racing cars, the coupling of small engines to KERS may improve the perception of racing being more environmentally friendly. The KERS is more a performance boost than a fuel saving device, permitting about same lap times with smaller engines
Boretti, Alberto
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