Summary Project Rotax 1503-4TEC

TFG Vctor Tizn Otero
My final project is about increase the performance of a Rotax 1503-4TEC Supercharged Intercooled engine to race in IJSBA Championships. I use the software SOLIDWORKS
and the AVL BOOST.
The title of my project is: Preparation of an engine to race in IJSBA (International Jet Sport Boating Association) championships in the Runabout Superstock 1600 class.
Simulation of the increase in the performance.
Firstly I dismounted the entire engine to take measurements and to build it up in Solidworks.
In the photos below are shown the steps that were followed to build up the entire engine in Solidworks:
Intake Manifold:
Exhaust Manifold:
Piston and Rod:
Butterfly Valve:
Head:
Rockers, springs, plugs, camshaft, etc.:
Camshaft and Intercooler:
Crankshaft:
Compressor:
Block, sump and balancer shaft:
Entire Engine:
Then, I built up the engine in AVL Boost to simulate it and to compare the data that AVL Boost will give with the data that the builder (BRP) gives.

First, I build up the engine scheme:

Then, I introduce the primary measurements of the engine into AVL:

I have also to introduce the measurements of the pipes. This measurements are: Length, diameter, hydraulic area, bending radius, friction coefficients, heat transfer
coefficients, etc.:

With the measurements that I cannot measure easily, I use the SolidWorks to help myself. With the measure tool and other operations I can measure difficult geometries
and areas, for example I can measure the heat exchange area of the cylinder head or the heat exchange area of an exhaust resonator:

Then, I introduce the data of the compressor. I introduce the compressor map and I rescale it to fit with my engine:
Compressor Map
2.6
0.6
0.5
Pressure Ratio (-)
0.3
60000
0.5
0.4
0.3
50000
0.3
0.6
0.7
0.6
45000
0.7
0.6
0.5
42000
0.4 42000
0.7
37000
0.6
0.5
0.4 37000
0.7
32000
32000
25000
25000
0.5 0.6 17000
17000
25000
0.7
0.7
10000
0.6
0.05
0.10.20.30.4 0.5 0.6 5000 0.5
0.50.5
0.5
0.6 0.7
1
0.4
1.8
0.05
0.1
45000
0.1
0.3
0.2
0.4
0.3
0.4
0.6
0.5
50000
0.7
0.6
0.7
0.7
Efficiency (-)
0.9
0.05
0.1
0.2
0.3
0.4
0.5
0.6
0.8
0.7
0.6
0.5
0.4
42000
0.8
0.2
37000
32000
0.15
0.3
0.7
0.7
0.1
0.7
0
0.2
Mass Flow (kg/s) (-)
0.25
0.3

Before run the simulation, it has to be a control of the simulation, where I indicate the fuel the engine runs (gasoline), I initialize the pipes and set the Case set, that are the
points where the engine will be studied:

And the software will give this results:
The power is the same that the power that the builder published.
(215 Cv @ 8.000 rpm)

In more detail, we could see that flow in exhaust valves in cylinders 2 and 3 have reflow, so in next steps we work to avoid that behaviour to increase the performance.
To race in the Runabout Superstock 1600 class, I have to see what changes are allowed by the rulebook. Once seen, I determine that the changes that I go to do in the
engine are the following:
To change the compressor, the camshaft, to adjust the fired and the injectors, to change the pipes and manifolds of intake and exhaust, and to change the pistons, rods,
valves and springs. Optionally I can rebore the cylinder, increase the compression ratio and increase the boost of the compressor if the engine runs on E85 fuel. E85 fuel is
allowed, but if the stewarts analyse my fuel and it isnt gasoline, I have to demonstrate that that fuel is E85 and not another different fuel, if I cannot demonstrate that my
engine is run on E85 fuel they will ban me. The rulebook also mark a limit for the noise up to 86 db. I set myself an upper limit of boost of 2.2 absolute bar to avoid
knocking.

The first component I will change is the compressor, so I introduce another compressor map with more boost to have more power:
Compressor Map
Pressure Ratio (-)
2.80.4
0.4
0.5
0.5
0.4
0.4
1.9
Efficiency (-)
0.7
0.6
55000
0.6
0.6
50000
0.7
0.7
0.9
0.7
0.8
0.7
0.7
0.7
50000
0.7
0.7
0.6
0.7
45000
0.5
45000
42000
0.7 42000
0.5
42000
37000
37000
0.7
0.4
37000
32000
25000 32000
25000
32000
0.4 0.50.6
17000
17000
25000
0.7
0.7
0.05
0.1
0.2
0.7
0.3
0.4
0.5
0.7
0.7
0.6 0.5 0.6 10000
0.6
5000
0.6
0.5
0.6
0.7
0.5 0.4 0.5
0.4
0.40.3
0.30.2 0.10.4
0.3
0.2
0.6
0.05
0.3
0.4
0
0.05 0.10.20.2 0.1
0.050.2
0.3 0.4 0.5
0.5
0.4
0.3
0.2 0.7 0.5
0.2
1
0
0.05
0.1
0.15
0.2
0.25
0.3
0.5
0.6
0.4
0.3
0.7
0.8
0.2
0.7
0.8
0.8
0.7
0.6
0.6
0.5
0.3
0.3
0.4
0.5
0.2 0.6
0.7
0 0.8 0.4
0.35
0.4
0.1
0
0.45
Mass Flow (kg/s) (-)

The results are the following: The power increases, but as we can se the inverse exhaust flow doesnt dissapear. Furthemore a reduction in the intake flow of the cylinder 3
apear.

Next change I will do is the change of the exhaust manifold:
As it can be seen, the reflow in the exhaust has decreased, and also the reduction of flow in intake.

Next step is to change the camshaft:
RESULTS
Intake
Exhaust
Open
Length
Open
Length
Series
350
255
130
230
Modificated
325
280
120
270
Intake
Exhaust
Overlap
Firing
AAA
RCA
AAE
RCE
Overlap
AE
Series
10
65
50
10
Modificated
35
65
60
30
65
10
Acronym are in Spanish: AAA = IO

PMS = TDC
PMI = BDC
RCA = IC
AAE = EO
RCE = EC
AE = TA

Then I will change the pipes and intake manifold:
Manifold
Series
Ducts
10
11
21
22
23
250
250
250
66.55
66.55
66.55
60-50
60-50
60-50
50
50
50
Modificated
16
17
18
Length (mm)
250
250
250
66.55
66.55
66.55
Diameter (mm)
50
50
50
55
55
55
Length (mm)
Diameter (mm)
Intake Pipes
Series
27
Length (mm)
90
150
250
170
188
272
350
60
100
Diameter (mm)
80
80
80
80
80-72
72-70
50-60
60
60
Modificated
22
Length (mm)
90
100
150
60
100
Diameter (mm)
150
90
90
90
90

Also we change the exhaust pipes, I have made a completely redesign of the pipes, so the noise doesnt exceed 86 db and the engine gains power:
PIPES
Series
16
17
18
19
20
515.74
181.2
676.59
150
1923.28
Diameter (mm)
65
60
65
65
70
Modificated
11
22
23
12
13
21
Length (mm)
300
250
100
250
300
250
Diameter (mm)
85
45
85
45
85
45
Length (mm)
PLENUMS
Series
PL2
PL3
PL4
PL5
1.806
1.18
1.806
0.2
Modificated
PL5
PL3
PL2
PL4
Volume (l)
1.5
1.5
2.354
Volume (l)
I finally got to eliminate the reflow in exhaust.

With a superficial treatment I can reduce the friction in the cylinder, and changing the lambda coefficient to inject more caudal of fuel the engine gains power:
Rpm
Series Engine Friction

(bar)
Modificated Engine
Friction (bar)
1000
0.6
0.4
3000
0.9
4500
1.5
1.4
6000
2.3
7500
3.3
2.65
9000
4.5
3.5
10500
5.9
4.5
Lambda changes from 14.7 to 12.5

Finally, I will do the optional changes, but only to show the increase of power that allow the E85 fuel, because Ill stay with the engine of 500 PS to be safe that I cannot be
disqualified if I cannot prove that I run on E85 fuel.
Optional changes are:
Compression ratio from 8.4 to 9.5

Rebored to 100.5mm
More boost, up to 2.5 absolute bar @9.000 rpm
Run on E85 fuel to avoid knocking

Once we have all the changes made, results can be compared:
Par = Torque
Rgimen de giro = rpm
Potencia = Power

Presin absoluta = Absolute boost presure
Consumo especfico = Specific consumption
Rendimiento Volumtrico = Volumetric Efficient
Presin = Cylinder Pressure
As it can be seen, the pressure rises from 110 bar to 208 bar in the modified version, so components will be subjected to greater efforts. To watch it easily, I will do a FEM
Analysis to watch the increase of efforts.
SF 3.5
Piston
Al 7075
The piston goes from a security factor of 3.5 to another of only 2
SF 2
Connecting Rod
Steel 4340
The rod goes from SF 4.24 to 3, but if we change the rod by another made of
Titanium, the FS rises to 5.
Series Engine
SF 4.24
Modificated Engine
SF 3
Ti Rod
SF 5
Valves
The same effects are seen in the valves, both intake and exhaust see how the
security factor decreases with the loads of the modified engine.
Exhaust
Steel 18NiCr5-4
Intake
SF 3.86
SF 3.8
SF 2.20
SF 2.14
Crankshaft
In the crankshaft the security factor decreases but is not critical.
Cast Carbon Steel
SF 5.36
SF 3
CONCLUSSIONS
As it can be seen, I increase the power from 215 PS to 500 PS run

on 95 RON gasoline and only with a boost pressure of 2.15 absolute
bar.
Even I could increase the power till and outstanding 600 PS of
power running on E85 fuel with a boost pressure of 2.5 absolute bar
and a compression ratio of 9.5 instead of 8.4.
The specific fuel consumption was also decreased at high revs.
All this with a noise lower than 86 db (A).
Always with low boost pressure, so there isnt risk of knocking.
The build-up in SolidWorks was so accurate that I equalled the
power that the builder published.
The difficulty was maximum because all this Ive made it without
expensive or advanced machinery, I did it in my home with in house
tools.
THANK YOU FOR YOUR

TIME AND ATTENTION
VCTOR TIZN OTERO, MECHANICAL ENGINEER SPECIALIZED IN
TRANSPORT AND ENGINES.
[email protected]

Summary Project Rotax 1503-4TEC

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What software did the author use for simulation?

What software did the author use for simulation?

What changes were proposed to increase engine performance?

What changes were proposed to increase engine performance?

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Piston and Rod:

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Rockers, springs, plugs, camshaft, etc.:

TFG Vctor Tizn Otero

Camshaft and Intercooler:

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Block, sump and balancer shaft:

TFG Vctor Tizn Otero

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TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

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Pressure Ratio (-)

Mass Flow (kg/s) (-)

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TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Mass Flow (kg/s) (-)

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Acronym are in Spanish: AAA = IO

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

I finally got to eliminate the reflow in exhaust.

TFG Vctor Tizn Otero

Series Engine Friction

Lambda changes from 14.7 to 12.5

TFG Vctor Tizn Otero

Compression ratio from 8.4 to 9.5

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Rendimiento Volumtrico = Volumetric Efficient

Presin = Cylinder Pressure

TFG Vctor Tizn Otero

The piston goes from a security factor of 3.5 to another of only 2

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

TFG Vctor Tizn Otero

Cast Carbon Steel

TFG Vctor Tizn Otero

As it can be seen, I increase the power from 215 PS to 500 PS run

TFG Vctor Tizn Otero

THANK YOU FOR YOUR

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