Supercharged KTM Engine for Snowmobile

The goal of this project is to design and manufacture a supercharged single-cylinder four-stroke engine that would package in a snowmobile chassis.
=Problem Definition=
The primary project objective will be supercharging a KTM 525 SX motorcycle engine with an M24 Eaton Supercharger and redesigning it to package inside a snowmobile chassis to achieve better fuel efficiency, more power, and reducing weight. 
==Background==
The University of Idaho Clean Snowmobile Challenge (CSC) Team is known for its work on lightweight, efficient, clean running, and other innovations for snowmobiles. Over the past sixteen years, the CSC team has been competing at the SAE International Collegiate Design Series interdisciplinary competition. The competition is held annually in Houghton, Michigan. The U of I team has won the competition in 2002, 2003, and 2007, and has acquired more than 50 awards. U of I's team is the only team in CSC history to win the aspired Founder's Trophy award back-to-back in 2015 and 2016.
Previous senior design project, seniors designed and manufactured a robust platform for testing and optimization for the next generation formula SAE vehicle utilizing the KTM engine.
==Deliverables==
* Solid-models of Eaton supercharger, plenum, new crankcase, mounts, and snowmobile engine bay 
* Math-models of engine/supercharger performance
* Achieve 80 hp with same engine displacement
* Remove stock engine transmission to interface with snowmobile CVT
* Incorporate an electric starter
* Functional prototype to fit in snowmobile chassis 
* Bill of materials and budget for functional prototype
* Manufacturing plans for functional prototype
==Specifications==
=Project Plan=
Engine:
* Decompression plate will be used to reduce compression rate to 8:1 to avoid knock
* Increase timing chain by one link
* New gaskets, spark plugs, and oil
* Electric start
Supercharger:
* Plenum design for efficient performance while reducing noise
* The supercharger will be mounted in an orientation such that the pulley lines up with the crankshaft
* The supercharger will run by a belt that is driven by the crankshaft
* The optimal running RPM will be determined for the supercharger and a pulley will be designed specifically to achieve that
* Air bypass so the supercharger does not have to run at lower RPMs
* Mounts for the supercharger
Crank Case:
* The stock engine transmission is not needed and will use the snowmobile CVT instead
* The crank case has two oil filters and will get rid of one and relocate it
* Create a smaller custom fabricated crank case that will fit in the snowmobile chassis
Snowmobile Chassis:
* Space available for new power plant
* Mounts for the supercharged engine
Intercooler:
* Snow to air intercooler to achieve better engine and supercharger efficiency
=Project Learning=
* The KTM engine was provided disassembled with a box full of parts. The engine reassembly process provided insight on engine functions. In addition, it allowed for brainstorming crankcase innovations and supercharger mounting. 
* Plenum design helps provide even air distribution into the valve, while reducing irregular velocity/pressure pulses and noise reduction due to resonating effects.
* Math models of the stock vs. supercharged engine (with potential intercooling effects) will provide empirical knowledge on supercharging advantages. 
Part	Description
 	Right casing half of the engine.
 	Left and right casings attached together.
 	Crankshaft, camshaft, piston, and cylinder head installed.
 	Flywheel and oil pump installed.
==Math Models==
Calculations	Description
 	Modeling representations between stock vs. supercharged engine, and relationship between Net Work output and Thermal Efficiency due to varying compression ratios
The Math Models will be further refined to incorporate specific supercharging elements such as changes in volumetric efficiency and stoichiometric fuel properties.
Additional parametric studies will be conducted to analyze stock and supercharged engine effects due to varying engine speed, supplied boost, and inlet temperature based on isentropic efficiency supplied by compressor maps and intercooling.
==Solid Models==
Part	Description
 	M24 Eaton Supercharger
0.393 L displacement per revolution
 	Plenum Design 1
Volumetric Capacity: 1.06 L
 	Plenum Design 2
Volumetric Capacity: 1 L
 	Decompression Plate
Thickness: 3.1 mm
 	Snowmobile Engine Bay
Estimated Volumetric Capacity: 5,014 in3
 	Stock KTM Engine in Chassis
 	Full Assembly of Stock Engine, Supercharger, and Plenum in Chassis
==Math Equations==
=Final Design=
Part	Description
 	New Crank Case Front View
 	New Crank Case Exploded View
 	Full Engine Assemby
 	Snowmobile Chassis
 	LEM Hybrid Motor
 	Snow to Air Intercooler
 	Plenum Design 3
Supercharger to Intercooler - 
Intercooler to Engine Intake
 	Full Engine Package in Snowmobile Chassis
 	Full Engine Package in Snowmobile Chassis Top View
 	Full Engine Package in Snowmobile Chassis Side View
 	Full Engine Prototype in Chassis
 	Full Engine Prototype in Chassis Side View
=Team Members=
	
Andy Hoang 
Major: Mechanical Engineering 
Hometown: Boise, Idaho 
Email: hoan5295@vandals.uidaho.edu		
Braden Connolly 
Major: Mechanical Engineering 
Hometown: Boise, Idaho
Email: conn1051@vandals.uidaho.edu
	
Nasser Aldawsari 
Major: Mechanical Engineering
Hometown: Dammam, Saudi Arabia
Email: alda9721@vandals.uidaho.edu		
Nathan Miller 
Major: Mechanical Engineering 
Hometown: Boise, Idaho
Email: mill2811@vandals.uidaho.edu
=Additional Documentation=
Project Schedule
Product Requirements
Bill of Materials
Budget
Presentations