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2002-01-0457
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2002-01-0457
ABSTRACT
DUAL PLENUM INTAKE MANIFOLD DESIGN
A new induction system has been developed, created,
and tested for use in the 2001 Formula SAE
competition. A 600 Honda CBR F4 four-stroke engine
intake is designed using dual plenums, which prevents
charging losses due to overlapping intake events at
low engine speeds. Dual butterfly valves actuated at
high engine speeds enable plenum volume
combination for improved high-end performance. The
intake restrictor venturi design has also been
improved.
INTRODUCTION
The Formula SAE competition is a nationwide event in
which teams of engineers representing competing
universities design, build, and race miniature Formula
One cars. Vehicles must undergo significant redesign
annually. Competition rules dictate specific guidelines
governing power train design and engine performance.
Engine displacement may not exceed 610 cubic
centimeters in a four-stroke design. The intake system
must include a 20-millimeter restrictor downstream of a
single throttle body controlling airflow.
The 2001 Lawrence Technological University Formula
Team selected a Honda CBR 600 F4 four-stroke
motorcycle engine.
The F4 engine was chosen
primarily due to its weight and power advantages over
similar class engines. The stock carbureted engine
was modified to a fuel-injected configuration, which
required the inclusion of cam position sensing for
accurate injection and spark timing. Electronic engine
control is accomplished through the use of a Motec
M48 ECU.
The restrictor creates the primary limitation on airflow
in the intake system, as it is the region of smallest
diameter. Maximum flow required at peak engine
speed was determined and used as a flow target for
intake component testing. The restrictor was designed
to incorporate a short entrance nozzle as well as a
long diffuser to minimize the impact of flow separation
prior to plenum entry. This nozzle and diffuser section
is referred to as the venturi [Figure 2].
Diffuser
Pressure
(kPa)
0.000
1.245
2.491
3.736
4.981
6.227
7.472
8.717
9.963
11.208
5 Degree
(m3/min)
0.000
1.586
2.209
2.665
2.990
3.242
3.438
3.576
3.670
3.721
6 Degree
(m3/min)
0.000
1.603
2.257
2.730
3.061
3.307
3.514
3.650
3.726
3.760
7 Degree
(m3/min)
0.000
1.623
2.246
2.684
3.016
3.276
3.472
3.616
3.707
3.735
Airflow (m^3/min))
2.5
2.0
5 Degree
1.5
6 Degree
1.0
7 Degree
0.5
0.0
20mm Restrictor
10
12
Pressure (kPa)
Intake
Valve Lift
(cm)
0.254
1995
Intake
1.415
1999
Intake
1.426
2000
Intake
1.446
2001
Initial
1.412
0.381
0.508
0.635
1.927
2.326
2.530
1.927
2.275
2.451
1.958
2.363
2.550
1.873
2.199
2.326
0.762
2.598
2.533
2.612
2.391
2001
Corrected
Smoothed
2000
90
hp
80
70
60
50
TORQUE
40
30
20
10
0
2000
4000
6000
8000
10000
12000
14000
RPM
100
Corrected
Smoothed
HP
90
Overlap Area
80
hp
70
60
50
torque TORQUE
40
30
20
10
0
0
2000
4000
6000
8000
10000
12000
14000
RPM
REFERENCES
1.
2.
3.
4.
5.
6.
APPENDIX
Calculations
Helmholtz Resonance Peak Determination
System Characteristics
Intake Manifold Runner Length
Limr
22.098
cm
Aimr
9.581
cm
Dro
4.7625
cm
Lip
8.9662
cm
Aip
7.3355
cm
ECR
13
DPC
149.75
Plenum Length
Lplen
27.000
cm
Aplen
32.774
cm
Ithr
Venturi Inductance
Ivent
Isr
0.4874
cm
oF
Speed of Sound in Air @ 42
Cs
335.28
m
s
cm
0.94488
cm
7.654
cm
1
1
1
Calculations
Intake Port Inductance
7.
8.
Lip
Aip
Iip
Iip = 1.2223
cm
Iimr = 2.3064
cm
Iplen = 0.8238
cm
C1 = 87.3542
cm
Limr
Iimr
Aimr
2000-01-3090.
Plenum Inductance
9.
Iplen
Lplen
Aplen
C1
DPC. ( ECR 1 )
2 ( ECR 1 )
Frequency Factor
fp
1 .
2.
Iimr) . C1
( Iip
fp = 0.0091
Primary Inductance
Iprim
Iip
Iimr
Iprim = 3.5287
cm
Secondary Inductance
Isec
Isr Ithr
Ivent
cm
Inductance Ratio
Isec
Iprim
a = 2.8084
3 . ( Limr. Aimr
Lip . Aip)
C1
8000
rpm
85
degrees
Cs = 335.28
m
s
Capacitance Ratio
b = 9.5299
Speed of Sound in Air
Calculation Constants
a. b
A = 30.5722
( 4. a. b)
Lp
B = 28.7681
2.
t . Cs. ( 100) .
360
1
12 . N.
60
Resonant Frequencies
f1
1 .
( A B)
.
.
2 2 a . b . Iprim. C1
f2
1 .
( A B)
.
.
2 2 a . b . Iprim. C1
Lp = 31.0874
f1 = 0.0095
Primary Runner Length
f1
fp
X1 = 1.0529
X2
f2
fp
X2 = 0.1836
( Aip. Lip )
Limr
Lip
2
Aprim = 8.9329
cm
Np
642 . Cs .
Aprim
. ( ECR
.
( Limr Lip ) DPC ( ECR
Np = 8732.7558
1)
1)
rpm
N1
N2
X1 . Np
X2 . Np
Lip
Limr = 22.1212 cm
X1
( Aimr. Limr)
Lp
f2 = 0.0017
Frequency Ratios
Aprim
Limr
cm
N1 = 9194.6952
rpm
N2 = 1603.2149
rpm