Variable Length Intake Manifold

2021-ME

The objective of this project is to design a variable length intake that increases the volumetric efficiency of the engine.

 

Team Members

Griffin Wurm | Ben DePrator | Cole Hickman | Gregory Nutter |

Project Poster

Click on any image to enlarge.

 

Watch the Project Video

video player icon

Download the Project Summary

video player icon

Project Summary

 

Overview

The Society of Automotive Engineers Club at Penn State Behrend participates in an annual competition to design and engineer a vehicle with the highest fuel efficiency as possible. Each year, projects are conducted by club members along with senior design students to continually improve the vehicle design and individual components. This year, the club requested a new intake manifold that would increase the volumetric efficiency of the engine without forced induction by redesigning the intake to optimize the fuel/air mixing. The selected intake design is variable in length, which increases the volumetric efficiency over a wider RPM range.

Objectives

The main objective of the project was to increase volumetric efficiency of the engine. More objectives included; increase air mixing, keep the intake lightweight and as small as possible, as well as keeping all manufacturing in-house if possible, to reduce overall cost.

Approach

  • Met with Supermileage team to discuss the background and general concepts of the project
  • Collected information on required specifications and desired outcome
  • Researched known information about single-cylinder engines as well as variable-length intakes
  • Generated multiple concepts based off the specification sheet
  • Graded the concepts based off performance criteria and decision matrices
  • Selected final design after multiple rounds of grading and iterating
  • Performed material selection ranking density, price, toughness, and thermal expansion coefficient
  • Produced a prototype to confirm dimensions and orientation within the workspace
  • Performed Modal Analysis and CFD Analysis to aid in the optimization process
  • Validated all analysis with hand calculations along with mesh convergence studies
  • Continuously worked alongside Supermileage team to ensure seamless integration of intake

Outcomes

  • The sponsor will notice a 14.83% increase in volumetric efficiency
  • Manufacturing is able to be kept in-house by utilizing 3D-Printing
  • The project kept the intake as lightweight as possible to minimize weight to aid in competitions
  • Created a design that is simple enough to promote future modification and improvements when applicable
  • Achieved a continuously variable intake that can adapt to future engine modifications or upgrades