P07222: FSAE Engine Management System For Electronic Fuel Injection

1. Member Role Erich Fiederlein Team Leader / Heat Transfer Analysis Andrew Bloom Programming Brandon Mancini Vibration Analysis Greg Doelger IC Engine Analysis / 3-D Modeling Kenvin Tung Digital Design / Embedded System Brad Greene Hardware Design P07222: FSAE Engine Management System For Electronic Fuel Injection Sponsor: RIT FSAE Team Faculty Advisor: Dr. Alan Nye

2. Customer Needs Engineering Specs Easy to tune and adjust User definable and intuitive interface Programmable from a laptop Cross platform, Zero configuration, USB interface Built in wideband o2 sensor Accurate to 0.1 AFR Watertight, vibration proof, reliable and durable Aluminum case with rubber dampners Potted Sealed Connectors Small and lightweight Less than 147mm x 105mm x 40mm Less than 0.5kg Data logging capability with run storage Ability to record past 20 minutes of sensor activity Flexible I/O Configuration Inputs: 8 Analog / 8 Digital Outputs: 16 Digital Project Description • Fuel and ignition control module for 4-stroke gasoline engine.

3. Design Concept

4. Design Concept

5. Design Concept

6. Risk Assessment • Damage to customer’s components • Sensors • Oxygen Sensor - Improper heater control circuitry • Fuel Injectors - Running over 80% duty cycle will cause failure • Engine • Timing Inaccuracies - propagation delays in firing fuel injectors or ignition can cause engine malfunctions and even damage • Damage to our components • Overheating - the case is water-tight and sealed, but the components will generate 45W of heat • Faulty Installation - a battery installed in reverse can destroy the electronics

7. Proposed Mitigation • Damage to customer’s components • Sensors • Computer simulations and substantial bench testing • Engine • Real time monitoring of outputs in the laboratory • Damage to our components • Overheating • Thermal analysis used in case development • Monitor temperatures during extended test runs • Faulty Installation • Over Voltage and Battery Protection circuitry

8. Current State of Design • Design meets all customer needs except • Auto tune, Wireless Telemetry, Knock Sensor, Integrated Display, Traction Control are all out of the scope of this project due to time constraints. • Design meets all engineering specifications • Still on track for proposed budget of $1200 • Budget COG (each) - $400 • Actual COG (each) - $362 • Mitigation • The system contains extra I/O and processing power to allow future expandability

9. Project Schedule Milestones • March 19th - PCB layout complete, and drawing package finalized, sensor input and processing routines begun • March 26th - Electrical/Mechanical components and PCB ordered, start implementation of output timer routines • March 31st - Functional prototype assembled, fuel and ignition map control added to program • April 2nd - Electrical hardware testing, serial communication (USB) completed • April 9th - Systems integration, thermal testing, GUI development resumes, design verification • April 16th - Embedded application testing begins, if necessary design revision • May 7th - Website constructed, electrical data sheet composed, design paper completed, poster fabricated • May 18th - Project review

10. Any Questions?