This study focuses on increasing the maximum torque band over a wide range of revolutions per minute (RPM) in order to increase efficiency and gain advantage over dynamic Formula Society of Automotive Engineers (FSAE) events. The intake with “variable runner length” is introduced to the 2021 race car of Team Ethan Racing. The optimum “runner length” range is chosen with two-dimensional (2D) iterations in “Ricardo WAVE” software, which is a one-dimensional (1D) engine simulation software with the goal of producing maximum torque band over a wide range of engine RPM. The engine used for this simulation was the Kraftfahrzeuge Trunkenpolz Mattighofen (KTM) 390 engine. The runner was simulated in a way to have different lengths at different RPM according to the size availability of the car. The plenum shape consideration was done quite smoothly, and also the volume consideration was performed extensively where the power and throttle response were considered simultaneously using the engine, as well as vehicle model for best possible optimization. Since this research was on a Formula Society of Automotive Engineers (FSAE) car, all of its rules were followed deliberately, and as a result, a small part regarding the nozzle was performed to get the optimized angle for the minimum pressure drop.Various manufacturing processes were studied and three-dimensional (3D) printing was decided to be the smartest option to go with. 3D printing filaments were decided based upon the functioning criteria of the intake parts. A sliding mechanism with linear actuator linkage was chosen, driven with a high torque servo motor. The motor was controlled with Arduino, which was connected to our engine Speeduino engine control unit (ECU).


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    Title :

    Computational Optimization of Formula Society of Automotive Engineers Car Intake Manifold with Variable Runner Using Ricardo WaveBuild


    Additional title:

    Sae Technical Papers



    Conference:

    Automotive Technical Papers ; 2022



    Publication date :

    2022-02-11




    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English





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