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Turbocharger Integration Design Review

This detailed design review covers customer needs, system architecture, compliance with requirements, risk assessment, testing plans, bill of materials, and timeline schedule for FSAE Turbocharger Integration project. Includes specifications, induction, turbocharger, boost control, exhaust system, and mounting details.

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Turbocharger Integration Design Review

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  1. Detailed Design Review P13222: FSAE Turbocharger Integration Thursday, November 8th, 2012 Kevin Ferraro, Phillip Vars, Aaron League Ian McCune, Brian Guenther, Tyler Peterson

  2. Agenda • Customer needs review • System architecture • Specifications overview • Review of compliance with requirements • Updated risk assessment • Testing Plans • Bill of Materials • Timeline/Schedule

  3. Customer Needs Review

  4. Specifications Table

  5. System Architecture • Induction • Turbocharger • Boost control • Engine • Exhaust system • Mounting

  6. Induction

  7. Spike Throttle

  8. Intercooler CFD and GT-Power Simulation Inlet, hot side: max spec temp from turbine outlet Inlet, cold side: ambient environment N=number of cells Width Thickness

  9. Turbocharger

  10. Turbocharger

  11. Boost Control

  12. Boost Control

  13. Boost Control

  14. Exhaust System

  15. Header Design

  16. GT-Power Simulation

  17. Mounting System

  18. Mounting

  19. Risk Assessment

  20. Testing Plans • Purchasing: Ti tube • Manufacturing: Throttle, plenum, plumbing • Initial setup/baseline • Dyno data collection, RPM sweeps: Horsepower, torque, AFR, BSFC, throttle position, etc • Labview: Dyno Controller software

  21. Testing Plans

  22. Bill of Materials

  23. Timeline/Schedule

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