The Formula SAE (FSAE) competition rules allow for a vast array of concepts developed by university teams to be competitive. Recent years of competition have seen cars utilising both single and multi-cylinder engine systems, space frame & monocoque chassis construction methods and various aerodynamic package designs take victory. Monash University won the 2011 and 2012 FSAE Australasia competitions utilising a single cylinder engine, whilst the same team won the previous two competitions utilising a four cylinder unit (SAE Australasia, 2012) – demonstrating that if well developed, a wide scope of possible engine packages can be competitively used.
A suitable design for a single cylinder FSAE-specification engine package has been developed, based upon a 2005 KTM 450SX motocross bike motor. This specified design comprises the intake system (including bellmouth, throttle body, restrictor, plenum chamber & intake runners) and exhaust system, tuned for optimum performance across a 4,000 rpm range of engine speeds (4,000 rpm – 8,000 rpm). Ancillary systems for the single cylinder enging package, including the cooling, oil/lubrication, electrical and packaging (ancillary) system are discussed.
Through Ricardo WAVE and Optimum Lap simulation, the developed engine package was compared to the performance of UQR’s existing Honda 4-cylinder engine, with the improved fuel economy, drivability & reduced mass of the single cylinder engine contributing to an estimated net gain of 11.378 Formula SAE competition points being scored from the Endurance/Economy events alone, despite the single cylinder car sacrificing 0.03 seconds per lap of speed to the current four cylinder car.