experimental engine dyno project

[MetroMPG]

And of course, it'll be useful to know what the MPG resolution / experimental margin of error will be with your test bed.

So cool!

[Daox]

I'd like to 3rd Oil Pan's and MetroMPG's suggestion of using cooled EGR to increase mileage.

[fujioko]

Originally Posted by MetroMPG

And of course, it'll be useful to know what the MPG resolution / experimental margin of error will be with your test bed.

So cool!

Hi 'ya MetroMPG...Good point,

This will certainly be subject to much debate. I'm starting this as a blank sheet in a matter of speaking.

I'm currently writing the software for fully automatic dyno control. The completed software will handle the entire test from beginning to end.

The initial test profile will be based on a 15 min expressway run. I have captured a few weeks worth of real world data and I need to do some sorting, averaging then match the real loads with the artificial loads with RPM being the target point and throttle position, MAP being secondary. Translating the realworld data into artificial loads will not be perfect but once the translation is complete I'll have a repeatable test profile.

Once I'm able to run a full test, we will see what the numbers look like. Your guess is as good as mine. Its going to be a bit fuzzy around the edges but we should have a solid baseline.

Of course I'll run the baseline profile a number of times and look for inconsistencies if any and sort out any problems.

With some math I can factor in gear ratios and work out the distance and figure MPG.

The end result will be profile 1.0. Other profiles will evolve as I get to know the limits of the dyno but we have to start somewhere.

I'm pretty much glossing over some major details because this is hard to explain but I am aware this is not a trivial task.

Anyway, at some point in the spring the project will be taken to the next level and true real world testing will begin with the B3 Miata.

This is going to be a cool show to watch!

Jim

[fujioko]

Originally Posted by Daox

I'd like to 3rd Oil Pan's and MetroMPG's suggestion of using cooled EGR to increase mileage.

An EGR experiment is in the works. Some minor issues need to be resolved. The Festiva engine doesn't have an actual EGR and I think it used virtual EGR that was based on camshaft timing.

Both the Miata and the dyno are equipped with roller a cam from a EGR equipped Ford Aspire but do not have EGR manifolds. At this point I'm not 100% sure the Aspire EGR equipped intake manifold will fit under the hood of the Miata.

Anyway, I'll get this sorted out one way or another and EGR will get tested.

Jim

[pgfpro]

Originally Posted by Xist

Why haven't any of us built a dyno? The most difficult part is deciding whether to follow "Building a Dyno for Dummies" or "The Idiot's Guide to Building a Dyno."

I could not imagine building one of these. Will we eventually have someone build their own wind tunnel?

Pgfpro, tell him how to convert to lean burn! Ah, dang, the Hydro Kid could do it, but where is he?

I would like to see him do some light load and mid load lean burn dyno testing?
Record TB position, MAP and of course the A/F ratio.

I would love to compare my lean burn road data with his results?

What I found that still puzzles me is on all my NA engines I could only get the engine to run so lean before a miss-fire? On my turbo engines I could run a lot leaner without any miss-fires.

I'M hoping a good friend purchases a Dyno Dynamics load type chassis dyno this next year. If everything goes to plan I will do some light load
ultra-lean burn testing with a exhaust analyzer to see NOx my levels?

[fujioko]

in reply to pgfpro,

Lean burn is a simple re-writing of my target A/F ratio table on the Megasquirt.

The B3 Miata is tuned to run fat in the margins and lean at cruise. My version of lean is 15 -15.2 AFR.

Completely unrelated, but related... recently I have noticed some trouble with the wideband and megasquirt reporting different A/F ratios. I believe the trouble is with the megasquirt and is yet to be resolved. Anyway, running a leanburn profile will be one of the tests.

Jim

[mechman600]

Wow, this is cool!
Are you going to measure NOx, CO & HC emissions as well? It's hard to see in your photo, but is there a cat installed?
I am sure some will agree that there is no real point in creating fuel saving tunes/devices if exhaust emissions are going to go way up.

[oil pan 4]

Originally Posted by Daox

I'd like to 3rd Oil Pan's and MetroMPG's suggestion of using cooled EGR to increase mileage.

You can use a diesel EGR cooler for multiple things. They are big, made of stainless steel and as long as you don't get one from a ford 6.0L it will last a really long time.
You can use them for their intended purpose, to cool EGR. Not a bad idea.
I say rout some of the actual waste exhaust through the diesel EGR cooler, in effect turning the "diesel EGR cooler" into a exhaust waste heat recovery heat exchanger, for faster warms up and so you can run the heat full blast as much as you want even in MN with out losing engine temperature.
You put the EGR cooler in your exhaust stream and then plumb it into your heater core circuit, instant heat or faster warm ups and to some degree both.

[Ecky]

Subscribed.

[kafer65]

That's a great idea for a reuse of the EGR cooler. The VW ones would work great and care taken to nurse the accordian pipe since they will crack after a long time vibrating. Man, I had one laying around in my garage I could have donated had I not scrapped it already.