An Investigation on the Design and Manufacturing of Powertrain System for Student Formula Japan (SFJ) Vehicle 2017-32-0110

The main purpose of Student Formula Japan competition (hereafter called “SFJ”) is to let students learn the basic ability necessary for engineers through design, fabrication and test projects. In this study the authors decided to adopt Honda BC-PC37E which was an engine for motor cycles. Then the engine have strength enough for the light weight, downsizing design. As the course of the competition consists of short straights and many corners for running within equal to or less than middle speed range, the engine must have excellent acceleration performance to reduce the lap times in the corners. The effective engine performance is necessary for the flat torque in all of engine speed range, especially in low engine speed range. As the regulation allows that a turbocharger is fitted to an engine, its introduction is effective for getting high torque in the low engine speed range. In this study the authors investigate the influences of the main specifications and the characteristics of important power train components, such as turbocharger, throttle, air restrictor, air collector, intake manifold (intake system), exhaust manifold (exhaust system), camshaft, valve timing and dual system of injection, on the improvement of the engine performance by analytical methods, experiments and driving tests. The conclusions are as follows: (1) The brake torque of the engine by adopting the turbocharger in the lower range of A/R (Area of inlet port/Radius of turbine, hereafter called “A/R”) has become higher in the low engine speed range. (2) In the case that the length of intake pipe is extended, the brake torque has been increased in the low engine speed range and decreased greatly in the high engine speed range.