FHSAE Next Generation Engine Configuration

To maintain a competitive advantage in the Formula Hybrid SAE competition, a new exotic and legendary engine design is needed for the University of Idaho race car. The solution is to reverse engineer a Honda CRF-150r one-cylinder engine with computerized micro measuring and laser scanning technology and turn it into a two-cylinder 250cc engine.

Background
The Formula Hybrid team at the University of Idaho is in need of a new engine configuration to remain competitive for future competitions. To incorporate the electric motor and maximize engine displacement, a new engine must be designed that has separate engine cylinders. This will require research of an engine with comparable features and design.

Deliverables
One of the main goals of this project will be to reverse engineer the Honda 150R engine, while this process is taking place we will be required to document any findings we make as well as how we took apart the engine. This project will require more than just reverse engineering the engine but it will also require that we learn to use the Metrology equipment and Solid Model the engine using the CAD program Solidworks. The Metrology equipment will help us measure the parts which can't be measured using ordinary tools such as a caliper and micrometer, by using devices such as a CMM and 3D scanner it will allow us to measure those parts. If we manage to complete these requirements the next task will be to downsize the engine from 150cc to 125cc, from there we will need to find a way to run two 125cc engines together to be placed in the formula hybrid car.

Metrology


Computerized Micro Measurement (CMM) at University of Idaho Metrology Lab

CAD Modeling
In order to draw complex shapes in Solidworks, it proved easier to scan or photograph images of parts and then trace them in Solidworks. This helped reduce the amount of dimensions we had to measure, it also speed up the process.



Matlab Simulation
The 150cc CRF-150r needs to be modified to a 125cc and fuel injected. We investigated building air fuel ratio (AFR) maps and optimizing spark timing. These images show theoretical power curves and brake specific fuel consumption (BSFC) for a 125 cc version of our engine. By reducing the engine size, a power loss of about 4 hp should be expected.

Following is the dimensions required to make our 150cc into a 125cc, these dimensions were used in the Matlab model: L = (36.5/1000);   Stroke of Engine [m] B = (66/1000);   Bore of Engine [m] l = (75.4/1000);         Length of Engine Connecting Rod [m] N_cyl = 1;         Number of Cylinders [unitless] C_r = 11.8;       Compression Ratio [unitless] N_r = 2;           Number of Revolutions Per Power Stroke IVC = 0;          Time [degrees] when Intake Valve Closes EVO = 314;         Time [degrees] when Exhaust Valve Opens

Document Archive
Documents (Meeting Minutes, Agendas)