Variable de-cat pipe and Factory exhaust pipe tested on Dyno

Variable de-cat pipe and Factory exhaust pipe tested on Dyno RPM De-cat exhaust pipe Factory exhaust pipe Power (kw) Torque (N.m) Power (kw) Torque (N.m) 2588rpm 10.6kw 148.8N.m 10kw 139.5N.m 2999rpm 23.9kw 288.8N.m 13.3kw 161.3N.m 3003rpm 24.8kw 299.1N.m 14.1kw 169.5N.m The above table explain the results on the engine Dyno between the factory exhaust pipe when it is running without load as well as the outcome once load is applied by installing a de-cat pipe. This result was accomplished by setting in three different engine speed and comparison among power (km) and torque (N.m).

Measurement

Measurement At 3850 rpm 1: Position of the butterfly-1.9kΩ 2: Pressure gauge reading-5kpa 3: Temperature at -250˚C 4: Pressure different at P1and P2=490.5N/s2 or 0.4905kpa Manometer reading Density of water=1000kg/m3 Force of gravity= 9.81m/s2 Height (h) =50mm or 0.05m N= (kg.m)/s2 Pressure of fluid= P= h. ρ.g P=0.05m×1000kg/m3 ×9.81m/s 2 P= 490.5kg/ms2 N= (kg.m)/s2 P=490.5kg/ms2×N/kg.m/s2 P=490.5N/s2 or 0.4905kpa Measurement At 4300 rpm 1: Position of the butterfly-2.69kΩ 2: Pressure gauge reading-6.8kpa 3: Temperature at -260˚C 4: Pressure different at P1and P2=539.55N/s2 or 0.539kpa Manometer reading Density of water=1000kg/m3 Force of gravity= 9.81m/s2 Height (h) =55mm or 0.055m N= (kg.m)/s2 Pressure of fluid= P= h. ρ.g P=0.055m×1000kg/m3 ×9.81m/s 2 P=539.55kg/ms2 P=539.55kg/ms2×N/kg.m/s2 P=539.55N/s2 or 0.53955kpa

Construction of manometer

A manometer can be built by filling a clear plastic tube with a coloured liquid to allow the fluid level to be easily observed. The tube is then bent into a U-shape and fixed in an upright position. The levels of the fluid in the two vertical columns should be the same or equal, as they are currently exposed to the same pressure. This level is therefore marked and identified as the zero point of the manometer. The manometer is placed against a measured scale to allow any difference in the height of the two columns. This height differential can be used directly to make relative comparisons between different test pressures. This type of manometer can also be used to calculate the absolute pressure when the density of the liquid in the manometer is known.Calculation The pressure exerted by a column of fluid can be given by the equation P = h.ρ.g this equation, P is the calculated pressure, h is the height of the fluid, g is the force of gravity and ρis density of the water. Because the manometer is measuring a pressure differential rather than an absolute pressure, we use the substitution P = Pa - P0. In this substitution, Pa is the test pressure and P0 is the reference pressure. Formula; Pressure=F/A, Volume=h.A, ρ=m/v orifice diameter=2.1cm or 0.021m Pressure of fluid= P= h. ρ.g radius=D/2 N= (kg.m)/s2 Force of gravity= 9.81m/s2 Density of water=1000kg/m3 Measurement At 3230 1: butterfly position-1.82kΩ 2: Pressure gauge reading-3Kpa 3: Temperature at -240˚C 4: Pressure different at P1and P2=19.62N/m2or 0.01962 Kpa Manometer reading Density of water=1000kg/m3 Force of gravity= 9.81m/s2 Height (h) =2mm or 0.002m N= (kg.m)/s2 Pressure of fluid= P= h.ρ.g P=0.002m×1000kg/m3×9.81m/s2 P=19.62kg/ms2 N=kg/ms2 P=19.62kg/ms2× N/kg.m/s2 P=19.62N/m2or 0.01962kpa

RPM-testing point

As we all know we install a throttle body in the middle of the pipe, the throttle body system as a piece of butterfly that we can control by the cable which connected to the throttle body of the 1UZ engine. The reason of why we still put the throttle position sensor (TPS) on is that we do not know how much angles of the butterfly moved. The TPS sensor we used is from a TOYOTA 4AFE engine throttle body, it has 4 PIN in side, and they are +5 volts (positive), ground (negative), signal output, and reference. At the first step we try to set up the +5v positive power and ground, then we used themultimeter test the signal output, but when we prepared everything it was hard to get the reading from the multimeter, so we give up this idea. In the next step we try to use the multimeter test the resistance of the TPS sensor. We try to find the positive and negative first, the resistance between positive and negative is 4.24KΩ, next step we used an idea it called "method of exclusion". To connect one of the wire (positive or negative we do not know), other side connect to one the rest 2 PINS, if the reading is infinity which means the pin is the reference, we can leave it alone, if have the reading and when move the throttle body the reading change at the same time which means this PIN should be signal output. When it connects the positive and signal output and move the throttle body from closed (idle) to fully open, the reading is from 1.58KΩ ～3.89KΩ. The Revolutions Per/ Minute (RPM) we can test by the multimeter as well, to select the RPM gear and find out the tachometer transmitter, our supervisor show us where it is, as you can see in the photo

Orifice calculation

Radius=D/2 r=0.055/2 r=0.0275 V= h × V=0.3 × π× 0.02752 V=7.13×10-4m3 Calculations above show the volume of the pipe which represents the volume flow of gas before encountering the orifices. Radius=D/2 r=0.021/2 r=0.0105 V= h × V=0.006× 0.01052 V=2.078m3 Calculations above show the volume of the pipe which represents the volume flow of gas after encountering the orifices.

Pressure gauge and Straight 4 inch diameter pipe

A back pressure gauge can be connected to the exhaust system one of several ways. By removing the oxygen sensor and connecting the gauge to the hole in the exhaust manifold by removing the air check valve in the air pump or plus air system, However on this design it is install on the pipe by drilling a hole just ahead of the butterfly to attach the gauge. On the rear end of the straight pipe, a (orifice) 2.1 cm or 0.021mmwasher is weld inside the diameter of the exhaust pipe in addition with two tiny 3mm tubes. The pressure one is measured by the tube that is fitted just ahead of the washer or orifice while pressure two is measured by the second tube which is located just after the air flow is restricted by the orifice.

make manometer

we pick up a piece of board from unitec and bought 4 meters 3mm tubes from miter10, then we made the manometer in the garage, it quite easy to make it, and also i bought a ruler to measure the reading