P07222: FSAE Engine Management System For Electronic Fuel Injection

Sponsor: RIT FSAE Team Faculty Advisor: Dr. Alan Nye

Member
Erich Fiederlein Andrew Bloom Brandon Mancini Greg Doelger Kenvin Tung Brad Greene

Role
Team Leader / Heat Transfer Analysis Programming Vibration Analysis IC Engine Analysis / 3-D Modeling Digital Design / Embedded System Hardware Design

Project Description
Fuel and ignition control module for 4-stroke gasoline
engine.

Customer Needs
Easy to tune and adjust Programmable from a laptop Built in wideband o2 sensor Watertight, vibration proof, reliable and durable Small and lightweight Data logging capability with run storage Flexible I/O Configuration

Engineering Specs
User definable and intuitive interface Cross platform, Zero configuration, USB interface Accurate to 0.1 AFR Aluminum case with rubber dampners Potted Sealed Connectors Less than 147mm x 105mm x 40mm Less than 0.5kg Ability to record past 20 minutes of sensor activity Inputs: 8 Analog / 8 Digital Outputs: 16 Digital

Design Concept

Design Concept

Design Concept

Risk Assessment
Damage to customers components
Sensors Oxygen Sensor - Improper heater control circuitry Fuel Injectors - Running over 80% duty cycle will cause failure Engine Timing Inaccuracies - propagation delays in firing fuel injectors or
ignition can cause engine malfunctions and even damage

Damage to our components

Overheating - the case is water-tight and sealed, but the components
will generate 45W of heat

Faulty Installation - a battery installed in reverse can destroy the

electronics

Proposed Mitigation
Damage to customers components
Sensors Computer simulations and substantial bench testing Engine Real time monitoring of outputs in the laboratory

Damage to our components

Overheating Thermal analysis used in case development Monitor temperatures during extended test runs Faulty Installation Over Voltage and Battery Protection circuitry

Current State of Design

Design meets all customer needs except
Auto tune, Wireless Telemetry, Knock Sensor, Integrated Display,
Traction Control are all out of the scope of this project due to time constraints.

Design meets all engineering specifications Still on track for proposed budget of $1200
Budget COG (each) - $400 Actual COG (each) - $362

Mitigation
The system contains extra I/O and processing power to allow future
expandability

Project Schedule Milestones

March 19th - PCB layout complete, and drawing package finalized, sensor
input and processing routines begun

March 26th - Electrical/Mechanical components and PCB ordered, start

implementation of output timer routines

March 31st - Functional prototype assembled, fuel and ignition map control
added to program

April 2nd - Electrical hardware testing, serial communication (USB)

completed

April 9th - Systems integration, thermal testing, GUI development resumes,

design verification

April 16th - Embedded application testing begins, if necessary design

revision

May 7th - Website constructed, electrical data sheet composed, design

paper completed, poster fabricated

May 18th - Project review

Any Questions?