Supercharged KTM Engine for Snowmobile
|Final Engine Package|
The goal of this project is to design and manufacture a supercharged single-cylinder four-stroke engine that would package in a snowmobile chassis.
The primary project objective will be supercharging a KTM 525 SX motorcycle engine with an M24 Eaton Supercharger and redesigning it to package inside a snowmobile chassis to achieve better fuel efficiency, more power, and reducing weight.
The University of Idaho Clean Snowmobile Challenge (CSC) Team is known for its work on lightweight, efficient, clean running, and other innovations for snowmobiles. Over the past sixteen years, the CSC team has been competing at the SAE International Collegiate Design Series interdisciplinary competition. The competition is held annually in Houghton, Michigan. The U of I team has won the competition in 2002, 2003, and 2007, and has acquired more than 50 awards. U of I's team is the only team in CSC history to win the aspired Founder's Trophy award back-to-back in 2015 and 2016.
Previous senior design project, seniors designed and manufactured a robust platform for testing and optimization for the next generation formula SAE vehicle utilizing the KTM engine.
- Solid-models of Eaton supercharger, plenum, new crankcase, mounts, and snowmobile engine bay
- Math-models of engine/supercharger performance
- Achieve 80 hp with same engine displacement
- Remove stock engine transmission to interface with snowmobile CVT
- Incorporate an electric starter
- Functional prototype to fit in snowmobile chassis
- Bill of materials and budget for functional prototype
- Manufacturing plans for functional prototype
- Decompression plate will be used to reduce compression rate to 8:1 to avoid knock
- Increase timing chain by one link
- New gaskets, spark plugs, and oil
- Electric start
- Plenum design for efficient performance while reducing noise
- The supercharger will be mounted in an orientation such that the pulley lines up with the crankshaft
- The supercharger will run by a belt that is driven by the crankshaft
- The optimal running RPM will be determined for the supercharger and a pulley will be designed specifically to achieve that
- Air bypass so the supercharger does not have to run at lower RPMs
- Mounts for the supercharger
- The stock engine transmission is not needed and will use the snowmobile CVT instead
- The crank case has two oil filters and will get rid of one and relocate it
- Create a smaller custom fabricated crank case that will fit in the snowmobile chassis
- Space available for new power plant
- Mounts for the supercharged engine
- Snow to air intercooler to achieve better engine and supercharger efficiency
- The KTM engine was provided disassembled with a box full of parts. The engine reassembly process provided insight on engine functions. In addition, it allowed for brainstorming crankcase innovations and supercharger mounting.
- Plenum design helps provide even air distribution into the valve, while reducing irregular velocity/pressure pulses and noise reduction due to resonating effects.
- Math models of the stock vs. supercharged engine (with potential intercooling effects) will provide empirical knowledge on supercharging advantages.
|Right casing half of the engine.|
|Left and right casings attached together.|
|Crankshaft, camshaft, piston, and cylinder head installed.|
|Flywheel and oil pump installed.|
|Modeling representations between stock vs. supercharged engine, and relationship between Net Work output and Thermal Efficiency due to varying compression ratios|
The Math Models will be further refined to incorporate specific supercharging elements such as changes in volumetric efficiency and stoichiometric fuel properties.
Additional parametric studies will be conducted to analyze stock and supercharged engine effects due to varying engine speed, supplied boost, and inlet temperature based on isentropic efficiency supplied by compressor maps and intercooling.
|M24 Eaton Supercharger
0.393 L displacement per revolution
|Plenum Design 1
Volumetric Capacity: 1.06 L
|Plenum Design 2
Volumetric Capacity: 1 L
Thickness: 3.1 mm
|Snowmobile Engine Bay
Estimated Volumetric Capacity: 5,014 in3
|Stock KTM Engine in Chassis|
|Full Assembly of Stock Engine, Supercharger, and Plenum in Chassis|
|New Crank Case Front View|
|New Crank Case Exploded View|
|Full Engine Assemby|
|LEM Hybrid Motor|
|Snow to Air Intercooler|
|Plenum Design 3
Supercharger to Intercooler - Intercooler to Engine Intake
|Full Engine Package in Snowmobile Chassis|
|Full Engine Package in Snowmobile Chassis Top View|
|Full Engine Package in Snowmobile Chassis Side View|
|Full Engine Prototype in Chassis|
|Full Engine Prototype in Chassis Side View|
Project Schedule File:Need 4 Speed Project Schedule .xlsx - Schedule.pdf
Product Requirements File:Need 4 Speed Product Requirements.docx.pdf
Bill of Materials File:Need 4 Speed Bill of Materials.xlsx - Sheet1.pdf
Presentations File:Engineering Release.pdf