Internal Combustion Engine Senior Design Group Supervising Professor Presenters: Dr. Dunn-Rankin Daniel Carpio Bert Salazar Marc Worrell Rick Chavez-Oropeza David Perales Ernesto Villasenor The Goal Design and build a working internal combustion engine laboratory. The engine is to be controlled by the user to run tests and analysis for different load and engine parameter cases. The steps in the process include the following: The engine’s electronics will be rewired to eliminate any unnecessary electrical connections. The IC engine’s original factory computer will be bypassed with a newly reconfigured chip. A throttle position device will be designed to the control the throttle electronically. A dynamometer will be installed to run load tests on the engine. Time Line of Events This table illustrates the time it will take to perform each step. October November December January Rewire Engine EECU and Troubleshooting engine Engine Running ignition system wiring harness and with its own computer ignition system and wiring harness Attempt Lean Burn Condition with Hydrogen injection February March April May Determine viability Troubleshooting between closed loop OPTO22 vs. Our control system IC Engine own algorithm Presentation Closed Loop PD Throttle PC Control position initiated linkage employed Basic Components Engine Stand Wiring Harness Engine Basic Components (cont..) Radiator and Fan Fuel Tank Housing Throttle Position Control An adapter plate will be designed and fabricated to change the position of the throttle body on the engine. The plate will enable the fitting of an electric motor to control the position of the throttle. An electric circuit will be Original Throttle Plate designed to control the motor, thus controlling the throttle position. Throttle Position Control (cont.) Original Shaft Fabricated Shaft Where throttle shaft is inserted Throttle Shaft Throttle Body The throttle plate will attach the throttle body to the original surface on the engine. The throttle shaft will have the exact dimensions of the original except for at the top, where a motor will be attached to the end of it. Throttle Position Control (cont.) Motor Adapter Plate Throttle Shaft 3-D Rendering of Entire Position Control Wiring Panel Rewire original wire harness removing unnecessary wiring. Replace prototype wire board with a new, easier one to use. Original Wiring Harness Provide a separation point in wiring to facilitate a quick change of control devices. Unused Wiring Wiring Panel (cont.) Battery Engine Wire Connector Strip Fuse Box Original On-board Computer Ignition Switch Wiring Board (prototype) This board will be replaced with a new encased metal switch panel. Control Chip Progress It has been determined that OPTO-22 was inadequate for our control needs. Controllers with required speed and flexibility have been researched. The input and output required by the engine has been identified and the general operating scheme by which the existing factory controller functions has been determined. The controller board search has been narrowed to four potential candidates. All of the controllers are available through Tern. (www.tern.com) The current and voltage requirements of the inputs and outputs must now be found so that one controller may be chosen. Dynamometer Unit has been purchased. Delivery is expected during the fifth week of instruction. A stand will be built for the installation of the Actual Dynamometer Unit dynamometer. The Dynamometer will be used to provide performance and power curves for various engine test parameters. .