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Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski

E85 Conversion Kit. Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski William Mehnert. Overview. Project Objectives Project Goals Project Background Design Approach Conceptual Design Ignition Timing Fuel Control

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Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski

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  1. E85 Conversion Kit Group 9A: Jerry Dutreuil Joshua Guerra Matt Grywalski William Mehnert

  2. Overview • Project Objectives • Project Goals • Project Background • Design Approach • Conceptual Design • Ignition Timing • Fuel Control • Closed Loop Control • Deliverables • Equipment needed • Budget • Nugget Chart • Project Management • Conclusion

  3. Project Objective • Convert a gasoline engine to operate on E85 without sacrificing fuel consumption, increasing performance and reducing emissions • Provide a control system unit to manage the engine

  4. Project Goals • Design a kit for the public to use without major modification to the engine • Understand the benefits of alternative fuels and the behavior of the engine using Ethanol-gasoline blends • Understand the effects of the different blends up to E85

  5. Project Background • Ethanol vs. gasoline • Octane number • Brake Specific Fuel Consumption • Heating Value • Production and Availability • Environment Protection Association standards • Existing products

  6. Design Approach • Engine Option • 1 cylinder Briggs and Stratton

  7. Design Approach (contd) • Engine Options • 1998 Suzuki GSXR 750cc • Open loop ECM

  8. Design Approach (contd) • Engine Option • 2001 Suzuki GSXR 600cc • Closed loop ECM

  9. Design Approach (contd) • Ignition timing Control • ECM: control spark timing and fuel • Encoder or crank angle sensor: measure crank angle to adjust timing • Control system design • Flex Fuel Sensor: Ethanol-Gasoline blend • Exhaust Gas Temperature: Optimize timing • O2 content sensor: Detect complete burn

  10. Why concentrate on Ignition Timing? • Directly affects combustion temperature • Combustion temperature affects emissions • Main cause of engine knock or pre-detonation • Effects power output • Must be adjustable to compensate for different blends of Ethanol-Gasoline

  11. Ignition Timing • Measured as degrees before Top Dead Center • Must leave time for flame propagation • Early ignition creates high pressures and engine knock leading to failure • Late ignition leads to poor power output

  12. Fuel Control • Directly affects Horsepower (heating value of fuel) • Adjust Air/Fuel ratios for proper combustion/emissions http://www.rceng.com/technical.aspx?UserID=230225&SessionID=SiEH2zhKsmej8veflxBT

  13. Feedback • Oxygen Sensor • Adjust fuel consumption • Flex Fuel Sensor • Determine ethanol mixture • Winter and summer blends, etc • Exhaust Gas Temperature • Chamber temperatures lead to detonation • Risk of melting internal components • Emissions • High temperature leads to high NOx • Low temperature leads to high HC

  14. Closed Loop system • FFS used for primary ignition table • Sensors used for trim values

  15. Deliverables • Emissions readings • CO • NOx • HC • Torque (HP Calculated) • Fuel Consumption • Sensitivity Analysis

  16. Equipment Needed • Engine – Fuel Injected with Electronic Timing • ECM – Megasquirt or Equivalent • Sensors – FFS, EGT, O2 • Dynamometer (Time) – Outsourced

  17. Budget

  18. Nugget Chart

  19. Project Management • Task Management • Research • Product Development • Refinement • Architecture • Engineering, tuning and testing • Deliverables

  20. Conclusion • With ignition timing, we will control the combustion in the cylinder chamber • We will provide a kit that will enable someone to run on E85/gasoline blend

  21. Thank you • Any Questions?

  22. Sensitivity Analysis • Timing vs. ALL • Use conservative Air/Fuel Ratios and measure against all Parameters for a specific RPM • Fuel vs. ALL • Use steady timing and measure all parameters for a specific RPM

  23. Reference • www.change2E85.com • www.megasquirt.info • www.flextek.com • www.e85fuel.com • www.eere.energy.gov • www.diablosport.com • www.e85vehicles.com • www.e85prices.com • www.aa1car.com • Effect of Advanced injection timing on emission characteristics of diesel engine running on natural gas • Effect of Ethanol-gasoline blends on engine performance and exhaust emissions in different compression ratio • The effects of ethanol-unleaded gasoline blends and ignition timing on engine performance and exhaust emissions

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