Anti-explosion integrated air inlet system of FSAE racing car and machining technology of anti-explosion integrated air inlet system

Abstract

According to the anti-explosion integrated air inlet system of the FSAE racing car and the machining technology of the anti-explosion integrated air inlet system, components of the anti-explosion integrated air inlet system are integrally formed, pressure fluctuation in the air inlet system can be slowed down, the engine inflation efficiency is improved by fully utilizing the resonance effect of engine air inlet airflow, and the power output performance is improved. When the air inlet system is manufactured, a high-temperature-resistant nylon material with high tensile strength is selected as a base material, a surface reinforcing layer is manufactured on the surface layer through high-temperature vacuum forming of pre-impregnated carbon fiber cloth and a thermosetting blue glue film, the overall tensile strength of the air inlet system is further improved, and the explosion-proof performance is enhanced. And the tensile strength and the anti-knock property of the whole air inlet system are enhanced while the light weight and the inflation efficiency of the engine are guaranteed to the maximum extent. The process can reduce the deformation degree of the inner blank of the pressure stabilizing cavity during thermocuring of the carbon fiber reinforcing layer as much as possible, ensures the smoothness of the inner wall of the air inlet system, and improves the inflation efficiency.

Description

Technical Field

[0001] The invention belongs to the technical field of FSAE formula racing cars, and in particular relates to an explosion-proof integrated air intake system of a FSAE racing car and a processing technology thereof. Background Art

[0002] The FSAE (Formula SAE) international student formula car, launched by the American Society of Automotive Engineers in 1979, is internationally regarded as the "Formula 1 of academia". The competition process requires each participating team to design and manufacture a small single-seat leisure racing car with excellent performance in acceleration, braking, and handling within one year in accordance with the competition rules and racing car manufacturing standards, and to successfully complete all or part of the competition. The competition rules limit the engine intake system to have a flow limiting valve with an inner diameter of 20mm. The existence of the flow limiting valve makes the engine operating conditions different from the design conditions of the original ECU, and the original ECU control fails. Each participating team must use a fully replaced ECU, design the intake system by itself to reduce the adverse effects of the flow limiting valve on the engine power output, and design the engine control program by itself to control the engine operation.

[0003] Among them, the control of ignition conditions has always been a major difficulty in overall machine control. Due to factors such as engine structure and changeable atmospheric environment, it is difficult for each participating team to calibrate a completely stable and reliable ignition control program. Cases of intake system explosions occur from time to time in each season. Explosions in the intake system can cause serious damage to the engine at the very least, or even endanger the lives of the participating team members. Therefore, it is very necessary to develop an intake system that is highly explosion-resistant, reliable and durable. Summary of the invention

[0004] The present invention provides an explosion-proof integrated air intake system for a FSAE racing car, a processing technology and an application thereof. The explosion-proof integrated air intake system has the advantages of high tensile strength and explosion resistance.

[0005] The technical solution of the present invention is as follows:

[0006] An explosion-proof integrated air intake system for a FSAE racing car, comprising an air intake manifold, a pressure stabilizing chamber and at least two air intake manifolds which are integrally formed and sequentially connected from top to bottom;

[0007] The intake manifold is waist-shaped, and the narrowest part of the intake manifold is the flow limiting valve;

[0008] The cross section of the pressure stabilizing chamber is circular or elliptical, the cross section of the pressure stabilizing chamber increases first and then decreases from bottom to top, and the connection between the pressure stabilizing chamber and the intake manifold is streamlined;

[0009] A bell mouth is formed at one end of the intake manifold, the intake manifold is communicated with the bottom of the pressure stabilizing chamber, and the bell mouth is located in the pressure stabilizing chamber.

[0010] In the above technical solution, the intake manifold, the pressure-stabilizing chamber and the intake manifold are integrally formed. This seamless design can maximize the tensile strength and explosion resistance of the intake system, avoid unnecessary air leakage, and reduce the possibility of overall cracking. At the same time, it provides greater convenience during disassembly and assembly, and has better reliability and maintainability.

[0011] The bell mouth of the intake manifold is located in the pressure stabilizing chamber. Air is taken into the pressure stabilizing chamber through the bell mouth, which reduces the intake resistance and the dissipation of intake airflow energy due to the resonance effect. The shape of the pressure stabilizing chamber is roughly hemispherical, and the transition between the intake manifold and the pressure stabilizing chamber is also streamlined. The synergistic effect of the intake manifold, the intake manifold and the pressure stabilizing tube can reduce the pressure fluctuation in the intake system, and make full use of the resonance effect of the engine intake airflow to improve the engine charging efficiency and power output performance.

[0012] In some preferred embodiments of the present invention, the front cone angle of the flow limiting valve is 16°, and the rear cone angle of the flow limiting valve is 8°. Further preferably, the volume of the pressure stabilizing chamber is 4700cc. Still further preferably, the length of the intake manifold is 200mm.

[0013] The volume of the pressure stabilizing chamber and the flow field structure of the intake system provided by the above technical solution can ensure the maximum smoothness of the engine intake airflow and reduce the pressure fluctuation of the intake airflow.

[0014] In some preferred embodiments of the present invention, the explosion-proof integrated air intake system further includes a throttle mounting seat, an intake air temperature and pressure sensor mounting seat, and an injector mounting seat;

[0015] The throttle valve mounting seat is arranged at one end of the intake manifold away from the pressure stabilizing chamber;

[0016] The intake air temperature and pressure sensor mounting seat is arranged on the side wall of the pressure stabilizing chamber, and the injector mounting seat is arranged on the end of the intake manifold away from the bell mouth;

[0017] A throttle valve mounting seat, an intake air temperature and pressure sensor mounting seat, an injector mounting seat, an intake manifold, a pressure stabilizing chamber and an intake manifold are integrally formed.

[0018] In the above technical solution, the intake air temperature and pressure sensor mounting seat and the injector mounting seat are integrally formed with other components of the intake system, further avoiding unnecessary air leakage and reducing the possibility of overall cracking.

[0019] In some preferred embodiments of the present invention, the explosion-proof integrated air intake system is made of glass fiber nylon material by 3D printing and curing after attaching a thermosetting blue adhesive film and pre-impregnated carbon fiber cloth on the surface. Further preferably, the glass fiber nylon material is 7200 nylon fiber, the thermosetting blue adhesive film is GXA120 toughened epoxy adhesive film, and the pre-impregnated carbon fiber cloth is T300 carbon cloth.

[0020] In the above technical solution, the intake system is manufactured using a glass fiber nylon material that is resistant to high temperatures and has high tensile strength. The surface layer is made of a thermosetting blue adhesive film and pre-impregnated carbon fiber cloth vacuum-formed at high temperature to form a surface reinforcement layer, which further improves the overall tensile strength of the intake system and enhances the explosion-proof performance. Specifically, after the thermosetting blue adhesive film is melted, the resin content of the pre-impregnated carbon fiber cloth can be increased and the adhesion between the carbon fiber layers can be improved. The heat-cured carbon fiber shell further improves the overall tensile strength.

[0021] A processing technology of the above-mentioned explosion-proof integrated air intake system comprises the following steps:

[0022] (1) performing 3D printing using a glass fiber nylon material as a substrate to obtain a first intermediate product;

[0023] (2) The outer surface of the first intermediate product is coated with a thermosetting blue adhesive film and pre-impregnated carbon fiber cloth, and then vacuum cured at 90° C. for 5 hours.

[0024] In the above technical solution, glass fiber nylon material is used instead of traditional photosensitive resin material as the substrate for 3D printing. Compared with photosensitive resin, glass fiber nylon material has lighter weight, higher hardness and tensile strength under the same volume, and better resistance to high temperature softening. The intake system is directly installed on the engine running at high temperature. The intake system has a higher resistance to high temperature softening, which can effectively prevent the intake manifold from cracking and fuel leakage when the engine is running. At the same time, the high temperature resistant substrate provides higher convenience for the subsequent high temperature vacuum forming process after coating the thermosetting blue glue film and pre-impregnated carbon fiber cloth.

[0025] In some preferred embodiments of the present invention, in step (2), a layer of thermosetting blue glue film and three layers of pre-impregnated carbon fiber cloth are sequentially coated on the outer surface of the first intermediate product, which can effectively improve the explosion-proof capability of the intake system.

[0026] In some preferred embodiments of the present invention, the specific operation of step (2) is: after the outer surface of the first intermediate product is coated with an epoxy film, the first intermediate product is filled with corundum with a particle size of not less than 800 mesh, and then vacuum cured at 90°C for 5 hours, and the corundum is removed.

[0027] In the above technical solution, diamond abrasive is added as the core filling material before vacuum curing, which can provide support for the first intermediate product during vacuum curing to prevent it from softening and collapsing during the vacuum process. In addition, diamond abrasive can also polish the inside of the pressure stabilizing cavity to improve its finish and reduce intake resistance.

[0028] The present invention has at least the following beneficial effects:

[0029] (1) The components of the explosion-proof integrated air intake system provided by the present invention are integrally formed, which can reduce the pressure fluctuation in the air intake system, make full use of the resonance effect of the engine intake airflow to improve the engine charging efficiency, and improve the power output performance.

[0030] (2) The intake system is manufactured using a high-temperature-resistant nylon material as the base material, and the surface layer is made of pre-impregnated carbon fiber cloth and thermosetting blue adhesive film vacuum-formed at high temperature to form a surface reinforcement layer, which further improves the overall tensile strength of the intake system and enhances its explosion-proof performance. While maximizing the lightweight and engine charging efficiency, the overall tensile strength and explosion resistance of the intake system are enhanced. This process can minimize the deformation of the endocast of the pressure stabilization cavity during the thermal curing of the carbon fiber reinforcement layer, while ensuring the smoothness of the inner wall of the intake system and improving the charging efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A schematic structural diagram of the explosion-proof integrated air intake system of the FSAE racing car provided in Example 1;

[0032] Figure 2 for Figure 1 Front view of;

[0033] Figure 3 for Figure 1 Reverse view of ;

[0034] Figure 4 for Figure 1 Left side view;

[0035] Figure 5 for Figure 2 Sectional view at A-A';

[0036] Figure 6-8 A physical photo of the explosion-proof integrated air intake system of the FSAE racing car provided in Example 1;

[0037] Fig. 9 The flow field simulation diagram of the pressure stabilizing chamber and the intake manifold in Example 1;

[0038] Fig.10 This is a flow field simulation diagram of the pressure stabilizing chamber and the intake manifold in Example 1.

[0039] The reference numerals in the figure are: 1-intake manifold, 11-limiting valve, 2-pressure stabilizing chamber, 3-intake manifold, 31-bell mouth, 4-throttle mounting seat, 5-intake temperature and pressure sensor mounting seat, 6-injector mounting seat. DETAILED DESCRIPTION

[0040] The technical solution of the present invention is further illustrated and described below through specific implementation methods. In order to facilitate the understanding of the embodiments of the present invention, the following will be further explained by taking specific embodiments as examples in conjunction with the accompanying drawings, and the embodiments do not constitute a limitation on the embodiments of the present invention.

[0041] The terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like used herein to indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific position, be constructed and operate in a specific position, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third" and the like are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0042] Unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0043] In this article, the front cone angle is the cone angle of the flow limiting valve away from the pressure stabilizing chamber, and the rear cone angle is the cone angle of the flow limiting valve toward the pressure stabilizing chamber. From bottom to top or from bottom to top refers to the direction from the end of the pressure stabilizing chamber connected to the intake manifold to the end of the pressure stabilizing chamber connected to the intake manifold.

[0044] Example 1

[0045] This embodiment provides an explosion-proof integrated air intake system (or air intake system) for a FSAE racing car, such as Figure 1-8 As shown, the air intake system includes an integrally formed intake manifold 1, a pressure stabilizing chamber 2, two intake manifolds 3 arranged in parallel, a throttle mounting seat 4, an intake air temperature and pressure sensor mounting seat 5 and an injector mounting seat 6.

[0046] Among them, the intake manifold 1, the pressure stabilizing chamber 2 and the intake manifold 3 are connected in sequence.

[0047] The intake manifold 1 is waisted, and the narrowest part of the intake manifold 1 is the flow limiting valve 11. The cone angle of the flow limiting valve 11 away from the pressure stabilizing chamber is the front cone angle, which is 16°, and the cone angle of the flow limiting valve 11 toward the pressure stabilizing chamber is the rear cone angle, which is 8°.

[0048] The pressure stabilizing chamber 2 is roughly hemispherical, and the cross section of the pressure stabilizing chamber 2 at any height is circular. Figure 1It can be seen from the figure that, from bottom to top, the radius of the cross section of the pressure stabilizing chamber 2 increases first and then decreases, and the connection between the pressure stabilizing chamber 2 and the intake manifold 1 is streamlined. Further, the volume of the pressure stabilizing chamber 2 is 4700cc.

[0049] from Figure 5 It can be seen that a bell mouth 31 is formed at one end of the intake manifold 3 , the length of the intake manifold 3 is 200 mm, the intake manifold 3 is connected to the bottom of the pressure stabilizing chamber 2 , and the bell mouth 31 is located in the pressure stabilizing chamber 2 .

[0050] The throttle mounting seat 4 is arranged at one end of the intake manifold 1 away from the pressure stabilizing chamber 2. The intake air temperature and pressure sensor mounting seat 5 is arranged on the side wall of the pressure stabilizing chamber 2. The injector mounting seat 6 is arranged at one end of the intake manifold 3 away from the bell mouth.

[0051] Through the above design, the tensile strength and explosion resistance of the intake system can be maximized, unnecessary air leakage can be avoided, the possibility of overall cracking can be reduced, and at the same time, the maximum smoothness of the engine intake airflow can be ensured and the intake airflow pressure fluctuation can be reduced. Fig. 9 and Fig.10 The flow field simulation diagram of this embodiment is shown in FIG. 1 . According to the simulation results, the intake air flow rate at the intake manifold is 5.328061*10 1 g / s, the air flow rate at the intake manifold is 5.328157*10 1 g / s.

[0052] The processing technology of the above-mentioned explosion-proof integrated air intake system includes the following steps:

[0053] (1) performing 3D printing using a glass fiber nylon material as a substrate to obtain a first intermediate product;

[0054] (2) A layer of thermosetting blue glue film and three layers of pre-impregnated carbon fiber cloth are sequentially coated on the outer surface of the first intermediate product, and then the first intermediate product is filled with corundum with a particle size of not less than 800 meshes. Finally, the first intermediate product is vacuum cured at 90° C. for 5 hours, and the corundum is removed.

[0055] Among them, the glass fiber nylon material is 7200 nylon fiber-reinforced, the thermosetting blue adhesive film is GXA120 toughened epoxy adhesive film, and the pre-impregnated carbon fiber cloth is T300 carbon cloth.

[0056] The above description is only a preferred embodiment of the present invention, and therefore cannot be used to limit the scope of the present invention. That is, equivalent changes and modifications made according to the patent scope of the present invention and the contents of the specification should still fall within the scope of the present invention.

Claims

1. An explosion-proof integrated air intake system for FSAE racing car, characterized in that: It includes an intake manifold, a pressure stabilizing chamber and at least two intake manifolds which are integrally formed and connected in sequence from top to bottom; The intake manifold is waist-shrinking, and the narrowest part of the intake manifold is a flow limiting valve; The cross section of the pressure stabilizing chamber is circular or elliptical, the cross section of the pressure stabilizing chamber increases first and then decreases from bottom to top, and the connection between the pressure stabilizing chamber and the intake manifold is streamlined; A bell mouth is formed at one end of the intake manifold, the intake manifold is communicated with the bottom of the pressure stabilizing chamber, and the bell mouth is located in the pressure stabilizing chamber.

2. The explosion-proof integrated air intake system according to claim 1, characterized in that: The front cone angle of the flow limiting valve is 16°, and the rear cone angle of the flow limiting valve is 8°.

3. The explosion-proof integrated air intake system according to claim 2, characterized in that: The volume of the pressure stabilizing chamber is 4700cc.

4. The explosion-proof integrated air intake system according to claim 3, characterized in that: The length of the intake manifold is 200 mm.

5. The explosion-proof integrated air intake system according to any one of claims 1 to 4, characterized in that: It also includes a throttle mounting seat, an intake air temperature and pressure sensor mounting seat, and a fuel injector mounting seat; The throttle mounting seat is arranged at one end of the intake manifold away from the pressure stabilizing chamber; The intake air temperature and pressure sensor mounting seat is arranged on the side wall of the pressure stabilizing chamber, and the injector mounting seat is arranged at an end of the intake manifold away from the bell mouth; The throttle mounting seat, the intake air temperature and pressure sensor mounting seat, the injector mounting seat, the intake manifold, the pressure stabilizing chamber and the intake manifold are integrally formed.

6. The explosion-proof integrated air intake system according to any one of claims 1 to 4, characterized in that: It is made of glass fiber nylon material through 3D printing and then cured after attaching thermosetting blue glue film and pre-impregnated carbon fiber cloth on the surface.

7. The explosion-proof integrated air intake system according to claim 6, characterized in that: The glass fiber nylon material is 7200 nylon fiber-reinforced, the thermosetting blue adhesive film is GXA120 toughened epoxy adhesive film, and the pre-impregnated carbon fiber cloth is T300 carbon cloth.

8. A processing technology for the explosion-proof integrated air intake system according to any one of claims 1 to 7, characterized in that: The steps include: (1) performing 3D printing using a glass fiber nylon material as a substrate to obtain a first intermediate product; (2) The outer surface of the first intermediate product is coated with a thermosetting blue adhesive film and a pre-impregnated carbon fiber cloth, and then vacuum cured at 90° C. for 5 hours.

9. The processing technology according to claim 8, characterized in that: In the step (2), a layer of thermosetting blue glue film and three layers of pre-impregnated carbon fiber cloth are sequentially coated on the outer surface of the first intermediate product.

10. The processing technology according to claim 8 or 9, characterized in that: The specific operation of step (2) is as follows: after coating the outer surface of the first intermediate product with a thermosetting blue glue film and pre-impregnated carbon fiber cloth, filling the first intermediate product with corundum with a particle size of not less than 800 mesh, and then vacuum curing at 90° C. for 5 hours, removing the corundum, and the product is ready.

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