Volkswagen Beetle Induction System Redesign

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Volkswagen Beetle Induction System Redesign

• ME 462
• Charles Le Boeuf
• Matthew Sease
• Gena Sangar

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Team Members and Roles

• ME Members
• Gena Sangar
• Matthew Sease
• Charles Le Boeuf
• Roles
• Product Manager (ECE Liaison)
• Product Design Engineer
• Manufacturing Engineer
• Detailer
• Drafter

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Project Description

• To upgrade the VW Beetle (circa 1932 to 1975)
  carbureted induction system to a modern EFI
  system.

Old System New System

• This includes
• Redesign of the air intake system.
• Redesign of the fuel delivery system.

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Market Analysis

• Carburetors are obsolete
• EFI attractive upgrade
• Beetles were Mass produced
• Use in vintage restoration and auto racing arenas
• Large potential market

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Design Objective

• To increase the volumetric efficiency of the
  engine.
• To improve horsepower.
• To improve torque.
• To improve fuel economy.

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Executive Summary

• Improvement Identified
• Current VW air and fuel delivery system
• Objective
• Innovative redesign
• Market research
• Methods
• Analytical research
• Numerical analysis
• Prototype design
• Manufacture
• Implementation
• Observation
• Results
• 13 of 14 engineering requirements were met or
  exceeded.
• 4 out of 18 were not able to be tested at this
  time, are anticipated to meet criteria well.
• With finished testing and revision, product will
  be ready for market.

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Analysis Approach

• Identify critical design criteria
• Identify Analytical Methods
• Identify FEA Simulation Methods

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Analysis and Modeling

• Analytical Methods
• Dynamic air system equations
• Mixture optimization (Stoichiometric combustion
  equations)
• Geometric optimization
• Simulation Methods
• COSMOS
• AFT Fathom

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Analysis and Modeling Cont.

• COSMOS FEA

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Analysis and Modeling Cont.

• COSMOS FEA

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Analysis and Modeling Cont.

• CAD Fuel System Layout

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Analysis and Modeling Cont.

• AFT Fathom

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Analysis and Modeling Cont.

• AFT Fathom

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Analysis and Modeling Cont.

• AFT Fathom

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Final Design

• Structural F.O.S. of 356
• Thermal F.O.S. of 2.5
• Tuned port geometry optimized at 4000 RPM (22
  length, 1.3 diam.)
• Fuel system specified (19 lb/hr at 45 PSI)
• Critical packaging parameters achieved

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Final Design
Fuel Pressure Gauge
Adjustable Fuel Pressure Regulator
Upper Runners
Fuel Rail
Down Tube
Throttle Body
Lower Runner
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Prototype Manufacturing

• Carbon Fiber Components Created

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Manufacturing Process
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Manufacturing Process
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Manufacturing Process
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Prototype Manufacturing

• Aluminum components machined

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Prototype Manufacturing

• Finished prototype components

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Prototype Manufacturing

• Test fit and Troubleshooting

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Prototype Manufacturing

• Component Specifications
• All sensors and components specified were OEM
  General Motors or equivalent (Delco/Delphi)
• Off-shelf availability
• Recyclability
• Maintenance friendly

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Areas of Improvement

• Revision B
• All braided stainless fuel lines
• In-line fuel pump
• Socket relief in injector block
• Fuel rail redesign to incorporate OEM retaining
  clips
• Move location of adjustable fuel pressure
  regulator
• Design steeper injector angle into injector
  blocks, incorporate long injector pintle
• Original throttle body design
• Tweak upper runner geometry on driver side fan
  shroud.

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Conclusion

• 13 of 14 engineering requirements that were
  tested met or exceeded expectations.
• 4 out of 18 were not able to be tested at this
  time, but are anticipated to meet criteria well.
• With finished testing and revision, product will
  be ready for market.

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Recommendations

• Finish the ECU testing and calibration.
• Test mechanical system to completion.
• Bring product to market.

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Special Thanks to

• Dr. Jie Chen Faculty Sponsor
• Rich Kenny Kenny Brown Performance
• Rick Steinard SPI Racing
• Professor Toksoy IUPUI
• Dave Crawford PDI
• John Kamler Axxis Power Racing
• Ron Kelley IUPUI
• Dr. Pidaparti IUPUI
• Dana Bradbury Machining
• SpA Technique
• North American Race Parts
• Stratasys Inc.
• Mike Kessler ME consultant
• John Spears Speartech
• Ben McCoy ECE consultant
• Arnab Star CD CFD Simulation
• Daniel Reed ECE consultant

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Discussion