Development, Testing and Calibration of Oxford Brookes V-Twin Engine

The powertrain is one of the most distinguishable and, arguably, most important aspects of a high performance or competition vehicle. For over a decade, the V-Twin project aimed to provide a superior powertrain package for the Formula Student entry of the Oxford Brookes team, as a flagship for the capabilities and commitment of the students involved. This research built on the thousands of hours already invested into the programme by students until 2013, to complete the mechanical and electronic development of the engine to run, test and calibrate the engine for the first time. This research investigated the mechanical development and calibration requirements of an otherwise blank sheet package, to derive a suitable base calibration for test cell operation. A bespoke control system was designed and manufactured, with particular attention to reliability, redundancy and robustness. Calibration of sensors and actuators was conducted in accord with theoretical understanding to create a safe base configuration for start-up attempts. A comprehensive analysis of the drivetrain was conducted to ascertain safe operating ranges to minimise risk of integrity loss and component failure. Datasets from each run were analysed to iteratively update the engine ancillaries, hardware and software, towards the objective of achieving acceptable idle quality at 3000 rev/min. Wide open throttle torque output at 3000 rev/min and 3500 rev/min was within 14% and 19% of one-dimension simulation results respectively. Encouraging BSFC (371g/kWh) and thermal efficiency figures (21%) were noted within this operating range, outside of the intended operating speed of such a high valve overlap configuration. The conducted research and development represent a key milestone in the decade long development of the V-Twin package, as a basis and encouragement for future development towards a target of vehicle installation. Recommendations have been made with regards to test cell and rigging upgrades to safely expand the engine speed and load sites that can be tested beyond those recorded in this research.

Grantor dc:publisher

Oxford Brookes University

Year dc:date

2020

Author dc:creator

• Stevens, Adam Christopher

Statement dc:rights

• All rights reserved

Language dc:language

en

DOI dc:identifier

https://doi.org/10.24384/fqkc-0t39

OAI identifier oai:identifier

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