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Competent engine design involves a combination of real-world experience and theoretical design. The Southwest Research Institute (SwRI) Light Duty Vehicle Emissions Group strives for a balanced combination of these two concepts.

Determining Optimum Engine Parameters

Using advanced design and analysis tools, engineers determine optimum engine parameters, including:

• Intake and exhaust system layout

• Piping length and diameter

• Plenum volume

• Cam profile

• Valve sizes

• Compression ratio

• Bearings

Modeling and Simulation

Engineers at SwRI use advanced computational fluid dynamic techniques to model and simulate the action of numerous gases and liquids in engine-related components and systems, including:

• Combustion chambers

• Fuel injection systems

• Fuel mixing

• Intake and exhaust ports

• Engine block and cylinder cooling

	SwRI's engineers use three-dimensional solid modeling to develop and optimize engines and components.

Applying Finite Element Analysis

SwRI conducts finite element analysis of all major engine assemblies and components such as:

• Cylinder heads

• Engine blocks

• Pistons

• Connecting rods

• Crankshafts

• Valve trains

• Fuel system components

Working with Powertrain Technology Limited

To better serve the small-engine industry, SwRI has formed a strategic alliance with Powertrain Technology Limited (PTL) for small engine design services. SwRI is now even more effective in designing and developing your new motorcycle or recreational vehicle powertrain. The staff excels in powertrain development for many reasons, including:

• Technology transfer – SwRI performs small engine design and development projects with the cooperation and support of our client's staff. This capability allows the client to provide constant input and direction to the project while also allowing their engineers to gain necessary knowledge of the design and development process.

• Intellectual property – As part of a long-held tradition, patent rights arising from sponsored research at SwRI are often assigned to the client. SwRI generally retains the rights to Institute-funded advancements.

• Location – SwRI is based in the continental United States and provides complete engineering and design services for small engine projects at the level and quality required for mass production motorcycles, recreational vehicles, and the utility market.

• Capabilities – A complement of services, including engine and transmission design, control system development, engine and powertrain testing, electromagnetic compatibility; noise, vibration, and harshness; and more, is provided by a single team.

• Experience – Our engineering and design staff expertise also includes complete engine and transmission design and development programs. We are also experienced with the small engine, motorcycle, and recreational vehicle industries.

Small Engine Design Capabilities

Our dedicated team of enthusiasts in the SwRI Light-Duty Vehicle Emissions Group can help you achieve all your goals and create a superior product. SwRI and PTL can assist your company with:

• Small engine design

• Full 3-D solids

• Concept to production, full 3-D solids

• Quality assurance and documentation systems

• Small engine analysis

• Comprehensive capability

• In-house and proprietary software

• Small engine parts/sourcing

• Prototype sourcing

• Global supplier selection

• Bill of materials (BoM)/cost control

• Small engine development

• Comprehensive test facilities

• Engines and transmissions

• Liaison with suppliers

• Final product engineering

• Cost reduction

• FMEAs

• Technology transfer with onsite client engineers

Flow Bench Facilities

	SwRI's flow bench facility where flow testing of intake ports is performed

Intake port performance has significant influence on engine power output, fuel economy, and exhaust emissions. Flow testing of intake ports is an integral part of total engine design and optimization. Southwest Research Institute (SwRI) maintains a flow bench facility with a flow capacity of 1,000 SCFM at 20 in. water differential pressure that is dedicated to port flow measurement and characterization.

Measurement of in-cylinder air motion is becoming increasingly important due to exhaust emissions and engine efficiency considerations. SwRI is the industry leader in measuring swirl, tumble, and combined air motion. SwRI's state-of-the-art design impulse swirl meters provide more accurate and repeatable measurements than other types of swirl meters.

Air motion for many sizes and types of engines is characterized on the SwRI flow bench facility. New cylinder head designs are compared to a large database of production and prototype heads.

Intake ports are parametrically designed using the latest solid modeling techniques. Intake ports are designed to provide the optimum balance between airflow and desired in-cylinder air motion characteristics. Parametric models of the ports are created based on fundamental engineering principles and years of port design experience.

 
Rapid Prototyping

	Rapid prototype models enable SwRI designers to quickly assess the suitability of a design for fit and function.

Southwest Research Institute offers rapid prototyping services using ABS plastic, nylon, stainless steel, titanium, and other metals. SwRI engineers utilize a solid imaging system called the SinterStation, which creates completely machinable plastic or metal parts directly from a 3D CAD file. SwRI also uses various methods of rapid prototyped patterns for “rapid casting” of various engine components to reduce development time. All that is needed is a 3D model converted into an .stl file (most CAD programs are capable of converting or exporting to STL, SLA, or RP). SwRI can also convert 2D drawings into 3D models, or a .prt file can be sent from PRO/E or SOLIDWORKS.

SwRI has experience with rapid prototyping many engine- and vehicle-related components, including:

• Intake manifolds

• Cylinder heads (2 and 4 stroke)

• Flowboxes to evaluate cylinder head port designs

• Brackets

• Crank case assemblies

• Connecting rods

For more information about small engine technology and engine design capabilities at SwRI or how you can contract with SwRI, please contact Jim Carroll at jcarroll@swri.org or (210) 522-5015.
 

| Emissions R&D | Engine, Emissions & Vehicle Research Division | SwRI Home |

Southwest Research Institute^® (SwRI^®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 12 technical divisions.

October 29, 2009