This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Variable Runner Length Intake Manifold Design: An Interim Progress Report
Technical Paper
2010-01-1112
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Manifold tuning has long been a critical facet of engine design
and performance optimization. This paper details the design,
analysis, and initial fabrication of a variable runner length
intake manifold for a restricted 2003 Suzuki GSXR 600 engine. A
series of analytical Helmholtz resonance calculations were first
performed to assess the feasibility of such a system. A
comprehensive CFD study was then performed using a combination of
Ricardo WAVE® and Fluent® simulations. Custom software was
developed to optimize restrictor geometry through fully automated
CFD simulations whose results were investigated to determine the
optimal transition for the intended flow characteristics. This
resulting candidate geometry was then used with a variable intake
design in a Ricardo WAVE® manifold dynamics model and was varied
iteratively to yield an optimum final geometry. This step-wise
design method was intended to minimize the computational expense
necessary to produce an acceptable design slated for
production.
A series of manufacturing processes was then developed to
fabricate the various intake components out of lightweight carbon
fiber or aluminum. Sliding mechanisms were actuated via a linkage
system powered by a small servo motor. This motor was controlled by
a Microchip dsPIC® microcontroller that was embedded into the 2009
Cooper Union FSAE® car's power distribution PCB. The controller
communicates with the engine's MicroSquirt® ECU over CAN to
read instantaneous engine speed and commands the servo based off a
empirically tuned lookup table. The system can be monitored
wirelessly over 802.11b.
Recommended Content
Citation
Vaughan, A. and Delagrammatikas, G., "Variable Runner Length Intake Manifold Design: An Interim Progress Report," SAE Technical Paper 2010-01-1112, 2010, https://doi.org/10.4271/2010-01-1112.Also In
References
- Winterbone, D. E. Pearson R. J. Design Techniques for Engine Manifolds Professional Engineering Publishing London 186058179X 1999
- Heywood, J. B. Internal Combustion Engine Fundamentals McGraw-Hill New York 0-07-028637-X 1988
- Cauchi, J. Farrugia, M. Balzan, N. “Engine Simulation of a Restricted FSAE® Engine, Focusing on Restrictor Modelling,” SAE Technical Paper, 2006-01-3651 2006
- McKee, R.H. McCullough, G. Cunningham, G. Taylor, J.O. et al. “Experimental Optimisation of Manifold and Camshaft Geometries for a Restricted 600cc Four-Cylinder Four-Stroke Engine,” SAE Technical Paper, 2006-32-0070 2006
- Blair, G. P. Cahoon, W. “Special Investigation: Design of an Intake Bellmouth,” Race Engine Technology 34 41 September 2006
- “MegaSquirt-IITM Controller Area Network,” http://www.megamanual.com/com/CAN.htm February 2009
- “MegaSquirt Source Code,” http://www.megamanual.com/files/code/main_v2.890.c February 2009