Instrumentation

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E85 Conversion Kit
The Green Solution of the Future
Final Design
Introduction Provide a control unit that will
allow a gasoline engine to operate on E85 while
maintaining fuel consumption, performance, and
emissions by optimizing operating parameters on
the fly. Design and test a unit that is easily
installed and allows users a FLEX-FUEL option.

• E85
• E85 is an environmentally friendly
  gasoline/ethanol blend composed of 85 ethanol
• E85 burns cleaner than gasoline
• E85 decreases dependence on foreign oil
• E85 is produced domestically benefiting the
  economy

• Design Features
• Operates using any blend of gasoline/ethanol,
  unlike other systems that run on only pure
  gasoline or pure E85
• Automatically optimized air/fuel ratio and
  Exhaust gas temperature to provide better fuel
  economy, power, and emissions than current
  systems on the market.
• Compensates for unforeseen changes, such as, E70
  winter blend (advertised as E85)

Operation Flowchart

• Technical Analysis
• Effects of ignition timing on power and
  emissions
• Effects of air/fuel ration on fuel consumption,
  power, and emissions

• Optimization
• Optimize system for best fuel economy at low
  throttle (highway cruising)
• Program for smooth transition from low throttle
  to high throttle
• Create optimum power, without reducing
  reliability, under full throttle conditions
• Maintain power, reliability, and drivability
  regardless of fuel mixture used

• Instrumentation
• Megasquirt ECU
• Megasquirt Stimulator
• Flex Fuel Sensor
• Wideband A/F Sensor
• EGT Sensor

Prototyping
A 1998 Suzuki GSXR 750 Motorcycle was used for
the prototype.

• Future Considerations
• More Compact design
• Piggyback installation
• Optimize programming and feedback
• Use of controller in future Formula SAE
  competitions
• Use of controller for lab experiments and lab
  experiments for future mechanical engineering
  students

The ECU was replaced with the MegaSquirt.
A series of sensors were installed throughout the
motorcycle to detect operating conditions.
Design Schematic
Project Team Joshua Guerra Matthew
Grywalski William Mehnert Jerry Dutreuil
The system was implemented into the motorcycle,
using software, the operating parameters were
optimized.
Project Advisor Professor Frank Fisher
STEVENS INSTITUTE OF TECHNOLOGY
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E85 Conversion Kit
E85 is the GREEN Fuel Alternative Project
Definition