Development of an engine variable geometry intake system for a Formula SAE application

The Formula SAE is an international competition for vehicle fully designed and built by students from worldwide Universities. The engine and vehicle design in the Formula SAE competition has to comply with a strict regulation. Regarding the engine intake line an air restrictor of circular cross-section no greater than 20 mm must be fitted between the throttle valve and the engine inlet. The aim of the throat is to limit the engine air flow rate as it strongly influences the volumetric efficiency and then the maximum power. The present paper is focused on the design of the engine intake system of the Firenze Race Team vehicle in order to optimize its performance in terms of both the maximum power and the drivability of the vehicle. One of the typical solutions for limiting the air restrictor influence consists of a plenum chamber placed along the intake line downstream of the restrictor. However the plenum involves also a delay in the engine response during the transient phases. The greater is the plenum, the lower are the power losses but the greater is the engine response delay. Taking advantage of a calibrated 1D model of the engine and a simplified vehicle model, the authors numerically analyzed an innovative solution that is constituted by a variable length duct inside the plenum. When the duct is at the maximum extension, the plenum is excluded from the intake line improving the engine response time. The optimization of the plenum volume and the definition of a preliminary control logic of the innovative system were done in order to obtain the maximum advantages in terms of both performance and engine drivability.