3cyl v1 Exhaust

Exhaust system development
Our customer wanted to improve the performance of the new engine. Based on the engine specifications we suggested three new exhaust system configurations. We designed and manufactured the prototypes ready for the performance testing on the engine dynamometer.

Theory of power
Exhaust system has a great influence on the performance of the internal combustion engine. It is actually the most cost effective solution to improve performance. With properly tuned exhaust system we increase performance, reduce emissions and thus influence driving characteristics.

Setting the goals
The client needed exhaust system for performance testing of the new engine in the R&D department. Main goal was to improve the performance and to find optimal construction for the production. We had to keep in mind the dimension constrains when the engine will be fitted into the vehicle.

Performance demands
Exhaust system has a big influence on the flow. It is basically an acoustic system which "guides" pressure pulses of the exiting exhaust gasses. With properly tuned exhaust system we can influence the power curve through the entire rpm range. Since maximum power has been set as a goal of the engine fine tuning was essential.

Dimension constrains
Diameter and length of exhaust system must adapt to the space around the engine. With these constrains in mind we can design different configurations. We connected together the cylinders to achieve positive scavenging.

Geometry concept
We designed three different configurations of the exhaust system. Connecting the cylinders depends on the ignition sequence. Shape of the collectors joining the cylinders must be designed in the way that it does not obstruct the flow. It also allows different variations to be put to the test as easy and as fast as possible.

Story behind the design
Air and fuel mixture that enters the cylinder of atmospheric internal combustion engine depends on the intake and exhaust system. If we want to increase the power we need to increase the amount of the air and fuel molecules trapped in the cylinder. Exhaust and intake channels are connected in the time of valves overlap.

Thinking about the production
Test system is quite different from the production version. Results from the test system are then transferred to the mass production model.

Structural analysis
Material and wall thickness of the exhaust system must withstand high temperatures and vibrations. Pressure pulsations inside the tubes might cause the pipe to crack.

Final results
At the end our customer managed to achieve a 2 kW increase of power over the desired rpm area. A big improvement with a properly tuned exhaust system!