The Formula SAE is a competition that challenges university students to design and build a formula style race car. The maximum capacity of the powerplant allowed is limited to 610 cc. The obvious choice is the motorcycle engines because of its outstanding power to weight ratio. The maximum power is limited by a 20 mm diameter restrictor, which is required by the rules of the competition. The restrictor has greatest effect above 8000 rpm because the maximum amount of air that can pass through the restrictor at that speed is not enough for the engine to run efficiently. Therefore the useful engine speed range is limited down to 3000 – 8000 rpm.
The major challenges for the engine group of the University of Queensland Formula SAE 2001 team is to overcome the handicap from the restrictor and maximize the power and torque in the useful engine speed range. To achieve the goal, new design of the intake and exhaust system as well as an aftermarket engine management are necessary. The common aim of all three systems is to maximize the power and torque in the mid-range of the engine speed.
The Helmholtz-Resonator tuning theory is one of the popular approaches for designing of intake and exhaust manifold. It is used to design this year’s intake and exhaust system. The Helmholtz-Resonator allows prediction of engine speeds that the tuning peaks would occurs. Unfortunately at the time this thesis is written, the engine is not tested yet, therefore no solid evidence of how well the predictions are.
The MoTeC engine management system is chosen for this year car. The MoTeC is relatively easy to set up when all the required sensors are mounted. The major problem was to set up the cam sensor on the cam cover and the crank trigger sensor. The problem was solved by making custom sensor mounts for both sensors. MoTeC has great reputation in racing industry for its user-friendly interface and the ability to unleash the potential of an engine. Unfortunately without testing results, there is no back up evidence in this thesis.