Design, Optimization and Calibration of a Single-Cylinder, Motorcycle Engine for Integration into a Novel Formula SAE Electric Hybrid Powertrain

The Formula SAE competitions often drive changes in the automotive research field by developing, implementing and emphasizing new technologies for both on-road and on-track applications and by training future engineers, mechanics, logistics and administrative personnel. In this work, the adaptation of a motorcycle, single-cylinder engine for the installation in an electric hybrid car for Formula SAE races is described, focusing on the design of intake and exhaust parts and on the development of the fully open-access Engine Control Unit (ECU) code. In the first part of the work, the 1-D model of the engine is developed and used to design the intake and the exhaust parts needed to make the Formula Student car rules compliant. In particular, the intake manifold and the intake ducts have been designed with the assistance of the engine model to optimize the engine response under transient conditions and to maximize the power. On the other hand, the exhaust line was designed to increase the performance ensuring that it was compatible with the noise regulations imposed by the competition. In the second part of the paper, the experimental activity for the development and calibration of the ECU control strategies is described. The authors highlight how the 1-D engine model helps to reduce the time and cost of the experimental campaign, reducing the number of components that have to be tested. Moreover, the main results of the calibration process are summarized in the last part of the work and the final installation of the engine in the Formula SAE car is shown.