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E85 Conversion Kit for Enhanced Engine Performance

Explore converting gasoline engines to E85 for improved performance and reduced emissions. Learn about ignition timing and fuel control for optimal efficiency and environmental impact. Project objectives include providing a user-friendly control system unit and designing a kit for easy public use.

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E85 Conversion Kit for Enhanced Engine Performance

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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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