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Elio Supplier Relations Vs. Possible Options Available

raptor213

raptor213

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Ekh said:
Thank you for an interesting and detailed look at the possibilities. Looks like the turbo might be harder to do than we all imagined ... perhaps including Paul, who has encouraged a turbo version all along.

Do your researches suggest non-turbo ways this thing can be made more powerful, using some of the existing Elio suppliers?
Click to expand...

A significant contributor to the Elio/IAV engine's unusually high compression ratio of 12.x:1 for a gasoline engine without forced induction is the incorporation of cooled external exhaust gas recirculation. A simple Google search would reveal telling articles that break down how EGR works in this particular application (non-diesel, small displacement, normally aspirated, fuel injected, etc).

I'm not sure if IAV designed the EGR cooler to operate off of engine oil or engine coolant fluid. Either way, the device itself is a simple heat exchanger, and the fluid used for cooling the bypass exhaust air must be circulated through its own process of cool-down so that its effectiveness can be sustained. This would involve a vacuum-tight closed loop through the OEM radiator or effective air cooling or something.

So, possible enhancements to this system could include an upgraded high-performance stock radiator or an auxiliary oil/coolant cooler mounted ahead of the front radiator similar to the way heavy-duty trucks have their transmission fluid coolers mounted.

Also, functional NACA hood scoops that channel free-stream boundary layer air into the engine compartment (without becoming a detriment to exterior aerodynamic flow) could provide a bonus of air-cooling the liquid-cooled EGR cooler if focused and channeled effectively.

Caveat: There is an inherent drag penalty by ducting high-speed air into the engine compartment without viable escape routes, but this could be mitigated by featuring specially located cowl vents below the engine bay, essentially forcing the air used for cooling to provide a multitasking purpose of energizing the undercarriage airflow as it races past a smooth skid plate and heads toward a custom rear diffuser that routes airflow around the high static pressure zone fore of the center-axis rear tire before slowing and expanding upward as it exits the rear of the vehicle underbody.

I fully intend on enhancing the fluid dynamics of the Elio's underbody airflow by installing a front splitter/spoiler, extended lower rocker panels along the sides, a smooth all-encompassing belly pan/skid plate from front bumper straight back to the rear wheel, a rear diffuser featuring vertical strake fins either side of the rear tire cavity, a functional rear spoiler, and vortex generators along the apex of the curvature of the roofline.

All of these enhancements would work in concert to add downforce (good for steering, stability, braking, efficiency) evenly from front bumper to rear bumper, and without creating unwanted aerodynamic lift at either end of the vehicle. At a stated 12XX# curb weight before accessories, we should all want our Elio's to stay firmly planted in all driving conditions.

Back to EGR - it's a relatively modern technology that's computer controlled to function differently with varying engine loads and driver demands. For instance, 15% of exhaust gas might be re-circulated under higher engine loads (such as accelerating from a stop) while 35% might be re-circulated at lower engine loads (such as high gear on the freeway with the cruise control set). So something as simple as a flash of the ECU map could result in a number of variables being adjusted to favor power, torque, acceleration, etc. over fuel economy.

Then there's cold air intake kits on the front side and aftermarket tuned exhaust systems on the back side that duly aid in reducing backpressure across the entire system, ensuring that the most molecules of air are as densely packed into the intake manifold as possible, because more air equates to more power during the combustion cycle.
 
raptor213

raptor213

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RUCRAYZE said:
You write so well, do you do this for living? Engineer??
thanks

X:XLV night all
Click to expand...

Began college as an astronomical engineering major, ended up pursuing professional pilot training. I've earned a living as a commercial pilot, flight instructor, aircraft dispatcher, and air traffic controller. I know a thing or two about basic principles of aerodynamics. And I have tinkered with automotive, motorcycle, and aircraft engines.
 
Ekh

Ekh

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raptor213 said:
A significant contributor to the Elio/IAV engine's unusually high compression ratio of 12.x:1 for a gasoline engine without forced induction is the incorporation of cooled external exhaust gas recirculation. A simple Google search would reveal telling articles that break down how EGR works in this particular application (non-diesel, small displacement, normally aspirated, fuel injected, etc).

I'm not sure if IAV designed the EGR cooler to operate off of engine oil or engine coolant fluid. Either way, the device itself is a simple heat exchanger, and the fluid used for cooling the bypass exhaust air must be circulated through its own process of cool-down so that its effectiveness can be sustained. This would involve a vacuum-tight closed loop through the OEM radiator or effective air cooling or something.

So, possible enhancements to this system could include an upgraded high-performance stock radiator or an auxiliary oil/coolant cooler mounted ahead of the front radiator similar to the way heavy-duty trucks have their transmission fluid coolers mounted.

Also, functional NACA hood scoops that channel free-stream boundary layer air into the engine compartment (without becoming a detriment to exterior aerodynamic flow) could provide a bonus of air-cooling the liquid-cooled EGR cooler if focused and channeled effectively.

Caveat: There is an inherent drag penalty by ducting high-speed air into the engine compartment without viable escape routes, but this could be mitigated by featuring specially located cowl vents below the engine bay, essentially forcing the air used for cooling to provide a multitasking purpose of energizing the undercarriage airflow as it races past a smooth skid plate and heads toward a custom rear diffuser that routes airflow around the high static pressure zone fore of the center-axis rear tire before slowing and expanding upward as it exits the rear of the vehicle underbody.

I fully intend on enhancing the fluid dynamics of the Elio's underbody airflow by installing a front splitter/spoiler, extended lower rocker panels along the sides, a smooth all-encompassing belly pan/skid plate from front bumper straight back to the rear wheel, a rear diffuser featuring vertical strake fins either side of the rear tire cavity, a functional rear spoiler, and vortex generators along the apex of the curvature of the roofline.

All of these enhancements would work in concert to add downforce (good for steering, stability, braking, efficiency) evenly from front bumper to rear bumper, and without creating unwanted aerodynamic lift at either end of the vehicle. At a stated 12XX# curb weight before accessories, we should all want our Elio's to stay firmly planted in all driving conditions.

Back to EGR - it's a relatively modern technology that's computer controlled to function differently with varying engine loads and driver demands. For instance, 15% of exhaust gas might be re-circulated under higher engine loads (such as accelerating from a stop) while 35% might be re-circulated at lower engine loads (such as high gear on the freeway with the cruise control set). So something as simple as a flash of the ECU map could result in a number of variables being adjusted to favor power, torque, acceleration, etc. over fuel economy.

Then there's cold air intake kits on the front side and aftermarket tuned exhaust systems on the back side that duly aid in reducing backpressure across the entire system, ensuring that the most molecules of air are as densely packed into the intake manifold as possible, because more air equates to more power during the combustion cycle.
Click to expand...
So, this boils down to exhaust gas recirculation for power, possibly re-mapping the computer to emphasize power over thrift, and aerodynamic tweaks via cowling, belly pan, and spoilers. EGR sounds like a complete engine re-design, so that's an unlikely mod for most of us. I'm pretty sure the Elio exhaust is already tuned -- for mpg efficiency, mainly.

I was liking the idea of an underbody tray for other reasons (noise reduction, protection against rocks, and aerodynamic improvement), and I hope Elio does offer one. The penalties for a tray are cost and weight. I suspect Elio is going to sit pretty tightly on their ECU instruction set. It would be nifty, though, if one could simply switch from "thrift" to "power" mode with a simple switch.

As for chin dams, lowering the rocker panels, and so forth, the practical penalties of those things vs. their performance gain lean me against them.

I guess we're going to have to rely on Elio to do the engineering, or maybe contact with Northsport if you want a one-off, all-out racing Elio.

Maybe some of the gear heads on the board have other ideas. How about it guys -- what are some cost effective ways to boost the Elio's performance?
 
electroken

electroken

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Ekh said:
Maybe some of the gear heads on the board have other ideas. How about it guys -- what are some cost effective ways to boost the Elio's performance?
Click to expand...

Certainly not cost effective, but if performance is the goal, start with a shorter stroke engine.

The time-honored recipe for power is to spin it faster (think 1966 Honda 450, 444cc, 45HP). If you start with a long stroke, the piston speeds get too high for reliability when you tach it up.
 
Frim

Frim

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Coss said:
I'm sure you heard of asking the time and getting how clocks work; well this includes the individual parts too.
In short TMI (TMI = Too Much Information)
Click to expand...

I am reminded of the Southerner who asked a New Yorker, "What time is it". The New Yorker replied, "You want to buy a watch?"
 
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