Group 9A: Jerry Dutreuil

1
E85 Conversion Kit

• Group 9A Jerry Dutreuil
• Joshua Guerra
• Matt Grywalski
• William Mehnert

2
Overview

• Project Objectives
• Phase Overview
• Phase 1
• Phase 2
• Bill of Materials
• Component Overview
• Software Flow Chart
• Program Logic
• Test Bed
• Nugget Chart
• 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
Phase 1 Overview

• Evaluation of design approaches (different
  engines)
• Research of existing products
• Ignition timing is most important aspect of
  performance

5
Phase 2 Overview

• Areas of Technical Analysis
• Ignition Timing
• Explosion Limits
• Emissions
• Power/Torque

6
Bill of Materials
Component From Price Function
Megasquirt (ECM) DIYAutotune.com 436 Engine Control
Exhaust temperature lethaldiesel.com 78 Timing Control
Oxygen Sensor Summitracing.com 200 Air/Fuel Ratio Control
Flex Fuel Sensor Gmpartsdirect.com 363 Fuel Composition
Fuel Injector Summitracing.com 250 Fuel adjustments
Engine E-bay or other used parts market place 1200 Testing
Dynamometer Local performance shop 80/test Testing
Emissions Local testing center 80/test Testing
E85 Fuel Closest E85 Station 2.75/Gallon Fuel
Misc Sensors and Circuits Mouser.com or Digikey.com 165 Control Circuits

Prices do not include taxes and shipping fees. Prices do not include taxes and shipping fees. Prices do not include taxes and shipping fees. Prices do not include taxes and shipping fees.

• Total 3,279.50

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Component Overview

• Megasquirt Standalone ECM
• Allows for full programmability and control of
  all engine parameters
• Allows for development of control algorithms

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Component Overview

• EGT Sensor
• Detects exhaust gas temperature (Chamber
  temperature)
• Oxygen Sensor, wideband
• -Detects air/fuel ratio

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Component Overview

• Flex Fuel Sensor
• Detects ethanol content in the fuel

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Software Flow Chart
FFS
Fuel
ECM
Injectors
Ignition
O2
EGT
Exhaust Gases
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Program Logic

• Read FFS to determine ethanol content
• Trim fuel table and timing table to compensate
• Read Oxygen Sensor
• Trim fuel values to bring values back to
  stoichiometric or towards desired target
• Read EGT sensor
• Trim timing values to adjust EGT temperatures to
  acceptable range and reduce emissions.
• Check throttle position
• Adjust timing and fuel lookup tables to create
  power as demanded.

12
Test Bed

• Track of dyno 24-96
• Track of current SAE car - 62
• Used to tune vehicle for power, torque, and
  emissions
• 5 Gas emissions testing

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Nugget Chart
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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
• The testing will consist of two identical runs
  one with gasoline and one with E85
• The results will be directly compared to
  determine to the differences in the theoretical
  values vs. the actual values.

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Thank you

• Any Questions?

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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
• http//www.eng-tips.com/viewthread.cfm?qid33615
• http//www.engineeringtoolbox.com/explosive-concen
  tration-limits-d_423.html
• http//www.allpar.com/fix/EPAMethods.html
• http//www.techedge.com.au/vehicle/wbo2/wblambda.h
  tm
• 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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Chemical Equilibrium

• Gasoline
• C8H1812.5(O23.76N2) ? CO23H2O12.5(3.76N2)
• Ethanol
• C2H5OH3(O23.76N2) ? 2CO23H2O3(3.76N2)

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Formulas Used