Beside the ECU given by Bosch Motorsport, our team work with several other electronics systems. One of these electronics projects is the design and implementation of the electronic water pump control. A unique controlling electronic system have been developed, that changes the velocity of the water circulation system depends on the temperature of the engine, to contol the engine heating and cooling process. The goal was to develop a system to control the engine cooling, which takes into consideration all parameters of the engine and the envirenment. Due to this system, the fuel consumption of the engine was reduced and the efficiency was higher. Telemetry systems on the market are really expensive, so our idee was to develop a unique telemetry system. The telemetry process can be divided into 3 tasks: Collecting measurement datas from the ECU through CAN bus, then transmissing the datas with the help of wireless system, displaying the received data real time on a computer. The analysing and following process of data can be handled with the computer program developed by the team.
The main part of the cooling circle is a Davies Craig EWP80 centrifugal pump, which has a maximum capacity of 80 l/min. The cooler is unique designed, dimensions are: 200x300x40. The fan has a capacity of 850 m^3/h, diameter is 190 mm. One of the most important part of the cooling system is the unique control unit, which changes the speed of fluid circulation depends on the engine temperature. With this process, the heating and cooling of the engine can be handled and we could achive efficiency growing and reduced fuel consumption.
Our team develops an engine for Formula Student usage, so we have to take many conditions into consideration. Dry-sump lubrication system was choosed instead of the wet-sump system used in vehicles in traffic, due to the high side-acceleration forces. The pattern for the oil tank was the tank of AUDI R8, with the appropriate parameters. The oil pump is mechanic and commercially available.
The crankcase is unique designed, splitted and the material is aluminium alloy. It was machined by Qualitative Production Engineering and Commercial Zrt, however the future plans contains using of casting technology. The most important future goal is to reduce the mass of the crankcase. The cylinder was casted by Nemak in Linz, the material is aluminium alloy as well. The bore is 100 mm. The crankshaft is splitted, similar to the motorcycle crankshafts. This effects, that the crankshaft has 3 main parts. Under the design process, the first objective was to reduce the rotating mass to grow the operating speed range. The maximal speed is 12000 rpm. The manufacturing and assembling of the crankshaft is made by our sponsors. Wolfram rods are used for mass balance, these are got into the holes of the webs by 10 tonne pressure. The piston, the conrod and the bolt are not unique parts, these are stock Prox parts.
The unique designed cylinder head was casted by Nemak in the prototype factory of Linz. The material is AlSi7MgCu0.5. The design of the intake and exhaust port is suitable for motorsport usage. The cylinder head has 4 valves, 2 camshafts and DOHC valve control. Chain is used for driving the camshaft. Rolling contact bearings are used for camshafts, because there bearings have better properties than slide bearings.
The task of this department is to design the parts on the intake and exhaust side of the engine. By both systems it is really important to meet the challenges of the the vehicle and rules of the Formula Student, so the succesful design can be achived with cooperation of many departments. During the design process we have to follow the limitations of Formula Student Rules for air intake systems. First the initial parameters, such as diameter and length of pipes and volume of airbox are determined by the engine simulation department. After that we have to consider the placement of the whole system in a race car. CFD programs are used for the appropriate design, and there are several flowbench measurments for feedback and checking. Manifacturing of the parts are executed by our manifacturig partners or by ourselves with the help of fiber composites. The design process of the exhaust system is similar to the air intake system. The simulating, designing and executive departments of the team are divided, but they cooperate really well. The continously development is really important related to both system to reach the potential of the engine.