Internal Combustion

Engine Senior Design Group

Supervising Professor Presenters:
Dr. Dunn-Rankin Daniel Carpio
Bert Salazar
Marc Worrell
Rick Chavez-Oropeza
David Perales
Ernesto Villasenor
The Goal
 Design and build a working internal combustion engine
laboratory. The engine is to be controlled by the user to run
tests and analysis for different load and engine parameter
cases.

 The steps in the process include the following:

 The engine’s electronics will be rewired to eliminate any unnecessary electrical
connections.
 The IC engine’s original factory computer will be bypassed with a newly
reconfigured chip.
 A throttle position device will be designed to the control the throttle electronically.
 A dynamometer will be installed to run load tests on the engine.
 Time Line of Events
 This table illustrates the time it will take to perform each step.

October November December January

Rewire Engine
EECU and Troubleshooting engine Engine Running
ignition system wiring harness and with its own computer
ignition system and wiring harness

Attempt Lean Burn

Condition with
Hydrogen injection

February March April May

Determine
viability Troubleshooting
between closed loop
OPTO22 vs. Our control system IC Engine
own algorithm Presentation
Closed Loop
PD Throttle PC Control
position initiated
linkage
employed
Basic Components

Engine Stand

Wiring Harness
Engine
Basic Components (cont..)

Radiator and Fan

Fuel Tank Housing

Throttle Position Control
 An adapter plate will be
designed and fabricated to
change the position of the
throttle body on the engine.
 The plate will enable the fitting
of an electric motor to control
the position of the throttle.
 An electric circuit will be
designed to control the motor,
Original Throttle Plate
thus controlling the throttle
position.
Throttle Position Control (cont.)

Original Shaft

Fabricated Shaft

Where throttle
shaft is inserted Throttle Shaft
Throttle Body
 The throttle plate will attach the throttle body to the original
surface on the engine.
 The throttle shaft will have the exact dimensions of the
original except for at the top, where a motor will be attached
to the end of it.
Throttle Position Control (cont.)

Motor

Adapter
Plate

Throttle
Shaft

3-D Rendering of Entire Position Control

Wiring Panel
 Rewire original wire harness removing unnecessary wiring.
 Replace prototype wire board with a new, easier one to use.
 Provide a separation point in wiring to facilitate a quick
change of control devices.

Original Wiring Harness

Unused Wiring
 Wiring Panel (cont.)
Battery

Engine

Wire
Connector
Strip
Fuse
Box

Original On-board
Ignition Switch
Computer
Wiring Board (prototype)

 This board will be replaced with a new encased metal

switch panel.
Control Chip Progress
 It has been determined that OPTO-22 was inadequate for our control
needs.
 Controllers with required speed and flexibility have been researched.
 The input and output required by the engine has been identified and the
general operating scheme by which the existing factory controller
functions has been determined.
 The controller board search has been narrowed to four potential
candidates. All of the controllers are available through Tern.
(www.tern.com)
 The current and voltage requirements of the inputs and outputs must
now be found so that one controller may be chosen.
Dynamometer
 Unit has been purchased.
Delivery is expected during
the fifth week of instruction.
 A stand will be built for the
installation of the
dynamometer.
 The Dynamometer will be Actual Dynamometer Unit
used to provide performance
and power curves for
various engine test
parameters.