Excavator energy-saving efficiency based on diesel engine cylinder deactivation technology

The hydraulic excavator energy-saving research mainly embodies the following three measures: to improve the performance of diesel engine and hydraulic component, to improve the hydraulic system, and to improve the power matching of diesel-hydraulic system-actuator. Although the above measures have certain energy-saving effect, but because the hydraulic excavator load changes frequently and fluctuates dramatically, so the diesel engine often works in high-speed and light load condition, and the fuel consumption is higher. Therefore, in order to improve the economy of diesel engine in light load, and reduce the fuel consumption of hydraulic excavator, energy management concept is proposed based on diesel engine cylinder deactivation technology. By comparing the universal characteristic under diesel normal and deactivated cylinder condition, the mechanism that fuel consumption can be reduced significantly by adopting cylinder deactivation technology under part of loads condition can be clarified. The simulation models for hydraulic system and diesel engine are established by using AMESim software, and fuel combustion consumption by using cylinder-deactivation-technology is studied through digital simulation approach. In this way, the zone of cylinder deactivation is specified. The testing system for the excavator with this technology is set up based on simulated results, and the results show that the diesel engine can still work at high efficiency with part of loads after adopting this technology; fuel consumption is dropped down to 11% and 13% under economic and heavy-load mode respectively under the condition of driving requirements. The research provides references to the energy-saving study of the hydraulic excavators.     

FEM Analysis on Acoustic Performance of Wall Flow Diesel Particulate Filters

Diesel powered vehicles, in compliance with the more strict exhaust emission standards such as Euro V, is likely to require a diesel particulate filter (DPF). A DPF used on a vehicle will affect the acoustic emission of the diesel engine, so it is important to investigate the sound propagation rule in DPF and further to propose the optimum DPF design. However, due to the geometrical complexity of the DPF, the traditional analysis method, such as analytical method, can not assess the acoustic performance of DPF accurately in medium and high frequency band. In this paper, a combined approach of finite element analysis and viscosity correction is proposed to predict acoustic performance of DPF. A simplified model of the full DPF is established and is used to analyze the sound propagation characteristic of the DPF. The distribution of the sound pressure and velocity, the transmission matrix of the DPF are obtained using the finite element method. In addition, the method of the viscosity correction is used in the transmission matrix of the DPF to evaluate the acoustic performance of DPF. Based on the FEM computation and the viscosity correction, the transmission losses under the rated load and idle condition of a diesel engine are calculated. The calculation results show that DPF can effectively attenuate exhaust noise, and sound attenuation increase with the rise of the frequency. Sound attenuation is better under rated condition than idle condition of diesel engine, particularly in frequency above 1 000 Hz.     

Comparative Analysis of Gas Emissions from a Vehicle Running on Ethanol and Natural Gas Fuel

It is known that the transport sector has a fundamental importance in the modem society, as the economic development is directly linked to mobility. Over the years, the transport became linked to different environmental problems, which can be detached greenhouse gases emissions in the atmosphere, where in recent decades can be perceived the intensification and targeting of efforts in research and development of new technologies to reduce the levels of greenhouse gases emissions in the atmosphere. In this context, it can be highlighted the modem systems of electronic engine management, new automotive catalysts and the use of renewable fuels which contribute to reducing the environmental impact. This research had, as its purpose, the analysis of fuels characteristics used for testing, comparative analysis of gas emissions from a motor vehicle running on ethanol or natural gas fuels according to NBR 6601 and conducting tests to estimate the maximum catalytic efficiency. For the implementation of trial, a flex vehicle was installed in a chassis dynamometer equipped with a gas analyzer, in order that before the completion of the urban driving cycle, were determined the content of hydrocarbons corrected, carbon monoxide corrected, carbon dioxide and oxygen present in gas emissions from the engine. The research concluded that： the performance analysis for characterization of fuel showed consistent with ANP specifications; after tests performances, it can be stated that natural gas fuel was the fuel which had the highest content of hydrocarbons and carbon monoxide corrected, while ethanol had the highest amount of carbon dioxide and oxygen residue present in gas emissions; before a comparative analysis, the vehicle catalyst showed the best performance for reducing the content of hydrocarbon corrected present in exhaustion gases when it worked with natural gas fuel and showed maximum efficiency of 100% to reduce the content of carbon monoxide corrected for both fuels. Before this, it can be stated that the vehicle catal     

HC-PM COUPLING MODEL FOR PARTICULATE MATTER EMISSION OF DIESEL ENGINES

A rapid, phenomenological model that predicts particulate matter (PM) emission of diesel engines is developed and formulated. The model is a chemical equilibrium composition model, and is based on the formation mechanisms of PM and unburned hydrocarbon (HC) emissions of diesel engines. It can evaluate the emission concentration of PM via the emission concentration of HC. To validate the model, experiments are carried out in two research diesel engines. Comparisons of the model results with the experimental data show good agreement. The model can be used to evaluate the concentration of PM emission of diesel engines under lack of PM measuring instruments. In addition, the model is useful for computer simulations of diesel engines, as well as electronic control unit (ECU) designs for electronically controlled diesel engines.     

EFFECTS OF COOLED EXTERNAL EXHAUST GAS RECIRCULATION ON DIESEL HOMOGENEOUS CHARGE COMPRESSION IGNITION ENGINE

The effects of cooled external exhaust gas recirculation (EGR) on the combustion and emission performance of diesel fuel homogeneous charge compression ignition (HCCI) are studied. Homogeneous mixture is formed by injecting fuel in-cylinder in the negative valve overlap (NVO) period. So, the HCCI combustion which has low NOx and smoke emission is achieved. Cooled external EGR can delay the start of combustion effectively, which is very useful for high cetane fuel (diesel) HCCI, because these fuels can easily self-ignition, which makes the start of combustion more early. External EGR can avoid the knock combustion of HCCI at high load which means that the EGR can expand the high load limit. HCCI maintains low smoke emission at various EGR rate and various load compared with conventional diesel engine because there is no fuel-rich area in cylinder..     

Breakup of cavitation bubbles within the diesel droplet

Supercavitation in the diesel nozzle increases the instability of droplets in part due to the two-phase mixture, while the effect of cavitation bubbles on the instability of drops is still unclear. In order to investigate the breakup of cavitation bubbles within the diesel droplet, a new mathematical model describing the disturbance growth rate of the diesel bubble instability is developed. The new mathematical model is applied to predict the effects of fluids viscosity on the stability of cavitation bubbles. The predicted values reveal that the comprehensive effect of fluids viscosity makes cavitation bubbles more stable. Compared with the viscosities of air and cavitation bubble, the diesel droplet＇s viscosity plays a dominant role on the stability of cavitation bubbles. Furthermore, based on the modified bubble breakup criterion, the effects of bubble growth speed, sound speed, droplet viscosity, droplet density, and bubble-droplet radius ratio on the breakup time and the breakup radius of cavitation bubbles are studied respectively. It is found that a bubble with large bubble-droplet radius ratio has the initial condition for breaking easily. For a given bubble-droplet radius ratio （0.2）, as the bubble growth speed increases （from 2 m/s to 60 m/s）, the bubble breakup time decreases（from 3.59 gs to 0.17 ps） rapidly. Both the greater diesel droplet viscosity and the greater diesel droplet density result in the increase of the breakup time. With increasing initial bubble-droplet radius ratio （from 0.2 to 0.8）, the bubble breakup radius decreases （from 8.86 trn to 6.23 tm）. There is a limited breakup radius for a bubble with a certain initial bubble-droplet radius ratio. The mathematical model and the modified bubble breakup criterion are helpful to improve the study on the breakup mechanism of the secondary diesel droplet under the condition of supercavitation.     

Source separation of diesel engine vibration based on the empirical mode decomposition and independent component analysis

Vibration signals from diesel engine contain many different components mainly caused by combustion and mechanism operations,several blind source separation techniques are available for decomposing the signal into its components in the case of multichannel measurements,such as independent component analysis(ICA).However,the source separation of vibration signal from single-channel is impossible.In order to study the source separation from single-channel signal for the purpose of source extraction,the combination method of empirical mode decomposition(EMD) and ICA is proposed in diesel engine signal processing.The performance of the described methods of EMD-wavelet and EMD-ICA in vibration signal application is compared,and the results show that EMD-ICA method outperforms the other,and overcomes the drawback of ICA in the case of single-channel measurement.The independent source signal components can be separated and identified effectively from one-channel measurement by EMD-ICA.Hence,EMD-ICA improves the extraction and identification abilities of source signals from diesel engine vibration measurements.     

SOFT SENSING MODEL BASED ON SUPPORT VECTOR MACHINE AND ITS APPLICATION

Soft sensor is widely used in industrial process control. It plays an important role to improve the quality of product and assure safety in production. The core of soft sensor is to construct soft sensing model. A new soft sensing modeling method based on support vector machine (SVM) is proposed. SVM is a new machine learning method based on statistical learning theory and is powerful for the problem characterized by small sample, nonlinearity, high dimension and local minima. The proposed methods are applied to the estimation of frozen point of light diesel oil in distillation column. The estimated outputs of soft sensing model based on SVM match the real values of frozen point and follow varying trend of frozen point very well. Experiment results show that SVM provides a new effective method for soft sensing modeling and has promising application in industrial process applications.     

Psychoacoustic study on contribution of fan noise to engine noise

There are more researches on engine fan noise control focusing on reducing fan noise level through optimizing fan structure,and a lot of research achievements have been obtained.However,researches on the effect of fan noise to engine noise quality are lacking.The influences of the effects of fan structure optimization on the engine noise quality are unclear.Thus,there will be a decline in fan noise level,but the deterioration of engine noise quality.Aiming at the above problems,in consideration of fan structure design and engine noise quality,an innovative method to analyze the contribution of fan noise to engine noise quality using psychoacoustic theory is proposed.The noises of diesel engine installing different cooling fans are measured by using the acoustic pressure method.The experiment results are regarded as analysis samples.The model of sensory pleasantness is used to analyze the sound quality of a diesel engine with different cooling fans.Results show that after installing 10-blade fan in medium diameter the sensory pleasantness at each test point is increased,and the increase is 13.53% on average,which indicate the improvement of the engine noise quality.In order to verify the psychoacoustical analysis,the subjective assessment is carried out.The test result shows the noise quality of engine installed10-blade fan in medium diameter is most superior.1/3 octave frequency spectrum analysis is used to study the reason of the improvement of engine noise quality.It is found that after installing proper cooling fan the sound pressure level below 400 Hz are obviously increased,the frequency assignment and spectral envelope are more reasonable and a proper cooling fan can optimize the spectrum structure of the engine noise.The psychoacoustic study is applied in the contribution of fan noise to engine noise,and the idea of engine sound quality improvement through the structure optimization is proposed.     

Investigation on Major Noise Sources of Vehicle Diesel Engine Based on Sound Intensity Measurement

In order to reduce the noise and vibration of the diesel engine,it is crucial to exactly identify the engine noise source character.Based on "two-microphone" method,the sound intensity measurement of a vehicle four-stroke diesel engine was carried out in a hemi-anechoic chamber.Then the sound intensity contour maps were obtained from the measurement results and the main noise components of different frequencies on all the measurement surfaces were picked out to construct contour maps.By analysizing the relationship between the characteristics of contour maps and the space distribution of the engine compartment,the major sources of the exterior radiation noise of the diesel engine were identified.The results provided a creditable basis for improving the noise performance of the engine in the next phase.     

OIL MONITORING DIAGNOSTIC CRITERIONS BASED ON MAXIMUM ENTROPY PRINCIPLE

A method of applying maximum entropy probability density estimation approach to constituting diagnostic criterions of oil monitoring data is presented. The method promotes the precision of diagnostic criterions for evaluating the wear state of mechanical facilities, and judging abnormal data. According to the critical boundary points defined, a new measure on monitoring wear state and identifying probable wear faults can be got. The method can be applied to spectrometric analysis and direct reading ferrographic analysis. On the basis of the analysis and discussion of two examples of 8NVD48A-2U diesel engines, the practicality is proved to be an effective method in oil monitoring.     

MODEL-BASED DEVELOPMENT OF REAL-TIME SOFTWARE SYSTEM FOR ELECTRONIC UNIT PUMP SYSTEM

A real-time operating system (RTOS), also named OS, is designed based on the hardware platform of MC68376, and is implemented in the electronic control system for unit pump in diesel engine. A parallel and time-based task division method is introduced and the multi-task software architecture is built in the software system for electronic unit pump (EUP) system. The V-model software development process is used to control algorithm of each task. The simulation results of the hardware-in-the-loop simulation system (HILSS) and the engine experimental results show that the OS is an efficient real-time kernel, and can meet the real-time demands of EUP system; The built multi-task software system is real-time, determinate and reliable. V-model development is a good development process of control algorithms for EUP system, the control precision of control system can be ensured, and the development cycle and cost are also decreased.     

MECHANISM ON DISTRIBUTION OF PILOT FUEL SPRAY AND COMPRESSING IGNITION IN PREMIXED NATURAL GAS ENGINE IGNITED BY PILOT DIESEL

Numerical simulations of pilot fuel spray and compressing ignition for pre-mixed natural gas ignited by pilot diesel are described. By means of these modeling, the dual fuel and diesel fuel ignition mechanism of some phenomena investigated on an optional engine by technology of high-speed CCD is analyzed. It is demonstrated that the longer delay of ignition in dual fuel engine is not mainly caused by change of the mixture thermodynamics parameters. The analysis results illustrate that the ignition of pre-mixed natural gas ignited by pilot diesel taking place in dual fuel engine is a process of homogenous charge compression ignition.     

Asymptotic analysis soot model and experiment for a directed injection engine

The existing soot models are either too complex and can not be applied to the internal combustion engine, or too simple to make calculation errors. Exploring the soot model becomes the pursuit of the goal of many researchers within the error range in the current computer speed. On the basis of the latest experimental results, TP (temperature phases) model is presented as a new soot model to carry out optimization calculation for a high-pressure common rail diesel engine. Temperature and excess air factor are the most important two parameters in this model. When zone temperature T?1 500 K and excess air factor Ф?0.6, only the soot precursors-polycyclic aromatic hydrocarbons(PAH) is created and there is no soot emission. When zone temperature T ≥ 1 500 K and excess air factor Ф?0.6, PAHs and soot source terms (particle inception, surface growth, oxidation, coagulation) are calculated. The TP model is then implemented in KIVA code instead of original model to carry out optimizing. KIVA standard model and experimental data are analyzed for the results of cylinder pressures, the corresponding heat release rates, and soot with variation of injection time, variation of rail pressure and variation of speed among TP models. The experimental results indicate that the TP model can carry out optimization and computational fluid dynamics can be a tool to calculate for a high-pressure common rail directed injection diesel engine. The TP model result is closer than the use of the original KIVA-3V results of soot model accuracy by about 50% and TP model gives a new method for engine researchers.     

Modified Pressure Loss Model for T-junctions of Engine Exhaust Manifold

The T-junction model of engine exhaust manifolds significantly influences the simulation precision of the pressure wave and mass flow rate in the intake and exhaust manifolds of diesel engines. Current studies have focused on constant pressure models, constant static pressure models and pressure loss models. However, low model precision is a common disadvantage when simulating engine exhaust manifolds, particularly for turbocharged systems. To study the performance of junction flow, a cold wind tunnel experiment with high velocities at the junction of a diesel exhaust manifold is performed, and the variation in the pressure loss in the T-junction under different flow conditions is obtained. Despite the trend of the calculated total pressure loss coefficient, which is obtained by using the original pressure loss model and is the same as that obtained from the experimental results, large differences exist between the calculated and experimental values. Furthermore, the deviation becomes larger as the flow velocity increases. By improving the Vazsonyi formula considering the flow velocity and introducing the distribution function, a modified pressure loss model is established, which is suitable for a higher velocity range. Then, the new model is adopted to solve one-dimensional, unsteady flow in a D6114 turbocharged diesel engine. The calculated values are compared with the measured data, and the result shows that the simulation accuracy of the pressure wave before the turbine is improved by 4.3% with the modified pressure loss model because gas compressibility is considered when the flow velocities are high. The research results provide valuable information for further junction flow research, particularly the correction of the boundary condition in one-dimensional simulation models.     

Fault diagnosis for manifold absolute pressure sensor(MAP) of diesel engine based on Elman neural network observer

Intake system of diesel engine is a strong nonlinear system, and it is difficult to establish accurate model of intake system; and bias fault and precision degradation fault of MAP of diesel engine can’t be diagnosed easily using model-based methods. Thus, a fault diagnosis method based on Elman neural network observer is proposed. By comparing simulation results of intake pressure based on BP network and Elman neural network, lower sampling error magnitude is gained using Elman neural network, and the error is less volatile. Forecast accuracy is between 0.015-0.017 5 and sample error is controlled within 0-0.07. Considering the output stability and complexity of solving comprehensively, Elman neural network with a single hidden layer and with 44 nodes is presented as intake system observer. By comparing the relations of confidence intervals of the residual value between the measured and predicted values, error variance and failures in various fault types. Then four typical MAP faults of diesel engine can be diagnosed: complete failure fault, bias fault, precision degradation fault and drift fault. The simulation results show: intake pressure is observable and selection of diagnostic strategy parameter reasonably can increase the accuracy of diagnosis;the proposed fault diagnosis method only depends on data and structural parameters of observer, not depends on the nonlinear model of air intake system. A fault diagnosis method is proposed not depending system model to observe intake pressure, and bias fault and precision degradation fault of MAP of diesel engine can be diagnosed based on residuals.     

STUDY ON FLUID THICKNESS BETWEEN POPPET AND VALVE GUIDE IN CONTROL VALVE OF INJECTOR

The physical model of -20 diesel oil and force model of injector control valve of common rail system is built. The changes of the fluid thickness are investigated on the base of the results of CFD and experiments for control valve of injector. The results indicate that a fluid thickness of 0.02-0.03 mm between the poppet and valve guide is sufficient to dampen any excessive control valve poppet bouncing.     

NUMERICAL SIMULATION FOR AIR AND AIR-PM FLOW IN WALL FLOW DIESEL PARTICULATE FILTERS

Numerical simulations are performed both for the single airflow and air-PM two-phase flow in wall flow diesel particulate filters (DPF) for the first time. The calculation domain is divided into two regions. In the inlet and outlet flow channels, the simulations are performed for the steady and laminar flow; In the porous filtration walls, the calculation model for flow in porous media is used. The Lagrange two-phase flow model is used to calculate the air-PM flow in DPF, for the dispersed phase (PM), its flow tracks are obtained by the integrating of the Lagrange kinetic equation. The calculated velocity, pressure distribution and PM flow tracks in DPF are obtained, which exhibits the main flow characteristics in wall flow DPF and will be help for the optimal design and performance prediction of wall flow DPF.     

FAULT DIAGNOSIS BASED ON INTEGRATION OF CLUSTER ANALYSIS, ROUGH SET METHOD AND FUZZY NEURAL NETWORK

In order to increase the efficiency and decrease the cost of machinery diagnosis, a hybrid system of computational intelligence methods is presented. Firstly, the continuous attributes in diagnosis decision system are discretized with the self-organizing map (SOM) neural network. Then, dynamic reducts are computed based on rough set method, and the key conditions for diagnosis are found according to the maximum cluster ratio. Lastly, according to the optimal reduct, the adaptive neuro-fuzzy inference system (ANFIS) is designed for fault identification. The diagnosis of a diesel verifies the feasibility of engineering applications.     

Numerical Analysis of Nozzle Clearance's Effect on Turbine Performance

Variable nozzle turbine (VNT) has become a popular variable geometry turbine (VGT) technology for the diesel engine application. Nozzle clearance, which can’t be avoided on the hub and shroud side of the VNT turbine due to the pivoting stators, can lead to turbine performance deterioration. However, its mechanism is still not clear. In this paper, numerical investigation, which is validated by experiment, is carried out to study the mechanism of the nozzle clearance’s effect on the turbine performance. Firstly, performance of the mixed flow turbine with fixed nozzle clearances tested on flow bench. Performance of the tested turbine with the same nozzle clearance is numerically simulated. The numerical result agrees well with the test data, which proves correct of the numerical method. Then the turbine performance with different nozzle clearances is numerically analyzed. The research showed that with nozzle clearance, flow loss in the nozzle increases at first and it reaches the maximum value when the clearance ratio is 5%. Flow at the exit of the nozzle becomes less uniform with nozzle clearance. The negative incidence angle of the rotor also increases with nozzle clearance and leads to more incidence angle loss in the rotor. The low energy fluid formed in the nozzle due to the nozzle clearance migrates from hub to shroud side in the rotor, which is another main reason for the rotor’s performance degradation. The present research exposed the mechanism of the dramatically decrease of the turbine performance with nozzle clearance: (a) The loss associated with the nozzle leakage increases with the nozzle clearance; (b) The flow loss grows up quickly in the rotor due to the incidence angle loss and migration of the low energy fluid from hub to shroud side.