Experimentally validated analytical modeling of diesel exhaust HC emission rate

Supercharged diesel engines are a key source of hazardous regulated emissions that have been extensively modelled, yet without explainable mathematical trends. The present paper demonstrates the analytical modeling of the percentage of unburned Hydrocarbon and the HC emission rate in four-stroke diesel engines for trucks. The study presents as well the analytical modeling of the supercharged air density. A sensitivity analysis has been conducted on these developed models. The study shows that the average percentage of deviation of the simulated results from the corresponding freeway cycles field data on the percentage of unburned Hydrocarbon and the HC emission rate is 10.6% and 4%, respectively. The corresponding coefficient of determination is 70% and 83%, respectively. The relative error of the developed models of the percentage of unburned Hydrocarbon and the HC emission rate is 10.6% and 2%, respectively. The study demonstrates with 99% coefficient of determination that the average percentage of deviation of the simulated results from the corresponding field data under the steady speed operating condition for all freeway cycles on the supercharged air density is 3.7%. The relative error of the developed model of the supercharged air density is 4%. These values of relative error are in an order of magnitude of deviation that is less than that of widely recognized models in the field of vehicle powertrain modeling, such as the CMEM. These developed analytical models serve as widely valid models that follow entirely from the principles of physics and the results of these developed models have explainable mathematical trends. The fact that these developed models are dimensionally correct further supports the validity of these models. The present models can help in better analyzing the performance of diesel engines and in developing and assessing the performance of these engines.     

Friction model of a marine diesel engine piston assembly

In modern marine diesel engines, power output and in-cylinder firing pressures are constantly increasing, leading to higher friction in engine components and especially in the piston assembly. A good understanding of the friction contributions of the various engine components is needed, if mechanical efficiency is to be improved. A friction model for the engine piston assembly has been developed and is presented in this paper. The model, based on lubrication theory, considers the detailed engine geometry and the complete lubricant action, and thus can be applied to a wide range of engines. In detail, the analysis takes into account the friction components of compression rings, oil control rings, piston skirt and gudgeon pin of the engine piston assembly. The model was applied to a four-stroke (medium speed) marine diesel engine and the effect of engine speed and load on friction was examined and compared with results from other semi-empirical models. The engine friction was predicted at constant rotational speed (generator operation) and variable rotational speed (propulsion operation).     

Diagnosis and condition monitoring of medium-speed marine diesel engines

Diagnosis of diesel engines is not new and various methods have been proposed in the past for fault diagnosis. The problems relating to marine diesel engines, especially medium- and high-speed engines, are due mainly to their large size, which does not allow the use of trial and error methods, and their high operating speed. The most difficult problem occurs when the engine is not able to produce its maximum power, while there is no obvious fault or error. In the present work a method is described which attempts to offer a solution to such problems. The method is a thermodynamic one based on a simulation model and the processing of measured engine data. Presented is an application of the method to a medium-speed marine diesel engine, which suffered from low power output accompanied by high exhaust gas temperatures. The results from application of the method show that the problem is not a direct one, but is caused by many factors that result in improper operation. With this method, the current engine condition can be discovered, and suggestions made for proper tuning or repair. After conducting such an analysis, a vessel was able to achieve its maximum cruising speed, showing that the proposed method is a promising one.     

柴油机动平衡问题的多体系统动力学仿真

如何确定曲柄连杆机构中平衡块的几何形状、质量特性参数以及辅助平衡装置的方案和参数，是柴油机设计人员需要考虑的主要问题之一。将三维CAD软件Pro-E和多体系统（MBS）动力学仿真软件Workingmodel 3D结合起来，建立了单缸柴油机曲柄连杆机构的多体系统动力学分析模型，并用该模型仿真研究了S195柴油机曲柄连杆机构在额定转速下的动平衡问题，为柴油机动平衡问题的分析计算及平衡装置的设计提供了一种新的方法。     

A methodology for cracks identification in large crankshafts

Diesel engines used in power plants and marine propulsion are especially sensitive to outage events. Any advance in the early detection of failure will increase the reliability of the electricity supply and improve its productivity by reducing costly power outages. Fault detection and diagnosis is important technology in condition-based maintenance for diesel engines. This article presents a classifier based on neural networks for identifying failure risk level in crankshafts, the engine component of greatest cost concern. The authors have developed a finite element model for crack growth that fits well with fracture appearance and produces the evolution of crankshaft stiffness with crack depth. A lumped system model of the engine uses this evolution as input, giving the instantaneous speed at the engine flywheel as a function of crack depth. All the results shown in the paper come from outputs of the simulation models which have been built from real engine data. Measurements of the instantaneous flywheel speed were not available due to the crankshaft failure. All data are extracted from this speed and are then classified using a Radial Basis Function neural network.     

油田柴油机最大功率现场测试系统及实验研究

针对目前的各类测功器均存在需要将柴油机拆卸后运回维修厂后才能测试、需外接负载、测试仪器庞大不易携带等缺点,提出了一种柴油机在不拆卸的情况下测试功率的原理和方法,给出一种柴油机加速、减速试验数据处理的方法。采用东华动态信号采集分析系统,用Visual Basic语言编写柴油机最大功率分析软件,得到柴油机转动惯量以及功率,研发出一种新的柴油机最大功率现场测试系统。通过现场试验,实地论证测试方法的可靠性。     

Pretreatment methods to improve the kinematic viscosity of biodiesel for use in power tiller engines

Biodiesel is an environmentally friendly fuel that can replace diesel in compression ignition engines without changing the engine structure. Biodiesel is typically manufactured from vegetable oils and animal fats, which give the fuel its oxidation stability and cold-flow properties, respectively. However, the kinematic viscosity of biodiesel can cause engine performance problems such as incomplete combustion and sludge formation due to insufficient fuel atomization. To address these problems, in this study, a pretreatment technology that lowers the kinematic viscosity of biodiesel made from blended animal fat and vegetable oil was developed. The results of application of the pretreated fuel to a single-cylinder power tiller engine indicated that it produced 88.3–99.8 % of the brake power produced by conventional diesel. In addition, although the pretreated biodiesel exhaust included increased amounts of nitrogen oxides and carbon dioxide emissions, the proposed fuel also decreased the amounts of hydrocarbon and carbon monoxide emissions compared with conventional diesel emissions.

     

Misfire and compression fault detection through the energy model

This article proposes a simple algorithm for misfire detection in reciprocating engines. The algorithm, based on an energy model of the engine, requires the measurement of the instantaneous angular speed. By processing the engine dynamics in the angular domain, variations in the working parameters of the engine, such as external load and mean angular speed, are compensated. A dimensionless feature has been abstracted for evaluation of the combustion as well as compression process of each cylinder. The proposed technique is expected to be easy to implement and to provide useful information for on-line monitoring of the in-cylinder processes in an internal combustion engine.     

Numerical research on influence of structural parameters of common-rail injector on injection rate of each nozzle hole

Performance of diesel engines are influenced by fuel spray distribution, fuel-air mixture formation and combustion, which are also influenced by hole-to-hole fuel injection rate from multi-hole injectors. In this study, a customized spray momentum flux experimental test rig was used to measure the transient injection rates from a two-layered 8-hole diesel injector. The results indicated that the fuel injection rate and the cycle fuel injection quantities of the lower-layered nozzle holes were 3–15% higher than the fuel injection rates and the cycle fuel injection quantities of the upper-layered nozzle holes. A three-dimensional (3D) computational fluid dynamics (CFD) model of the two-layered 8-hole diesel injection nozzle was developed and validated by analyzing the relative error between the numerical results obtained from the model and the experimental results measured with the test injector. The simulation results showed that the relative average deviation of hole-to-hole cycle injection quantities were less than ±1%, which is the result of 5% increment in the cross-sectional area of the upper-layered holes.     

Simulation of combustion in a porous-medium diesel engine

The future internal-combustion (IC) engines should have minimum emissions level under lowest feasible fuel consumption. This aim can be achievable with a homogeneous combustion process in diesel engines. We used a porous medium (PM) to homogenize the combustion process. This research studies simulation of a direct-injection diesel engine, equipped with a chemically inert hemispherical PM. Methane is injected into a hot PM, assuming mounted up the cylinder in head. Combustion with lean mixture occurs inside PM. A numerical model of PM engine was carried out using a modified version of the KIVA-3V code. PM results were evaluated with experimental data of unsteady combustion-wave of methane in a porous tube. The results show the mass fraction of methane, CO, NO and temperature in solid and gas phases of the PM and in-cylinder fluid. Also presented are the effects of injection timing and compression ratio on combustion.

     

一种新型复合式电磁驱动燃气喷射装置的设计与分析

作为国际远洋船舶的主要动力装置,采用加入气体燃料的低速柴油机在实现节能减排方面拥有巨大潜力。燃气喷射装置作为缸内直喷的核心执行机构,对内燃机燃烧品质和热效率有着重要影响。针对现有电磁驱动喷射装置存在的流量小、驱动力弱等不足,提出一种新型复合式电磁驱动燃气喷射装置。首先,针对驱动机构及阀体提出新的设计思路,通过有限元方法分析了驱动机构的电磁特性及阀体流动特性,验证了设计可行性;其次,建立喷射装置的CFD仿真模型,归纳了流量特性规律;最后,建立试验平台,测试了驱动机构的稳/动态特性。仿真与试验结果表明,新型复合式电磁驱动燃气喷射装置具有高效节能、快响应、高精度的动态特性,对缸内预混特性等具有显著的改善效果。     

An investigation on the performance of a Brayton cycle waste heat recovery system for turbocharged diesel engines

A Brayton cycle waste heat recovery (WHR) system for turbocharged diesel engines was proposed and the performance of a diesel engine integrated with the proposed system was investigated. The waste heat recovery system is integrated with the turbocharging system of diesel engines, using the turbocharger compressor as the Brayton cycle compressor. The engine cycle simulation code GT-Suite 7.0 was used to investigate the performance of a diesel engine integrated with the WHR system. A Brayton cycle turbine was designed and its performance was simulated with a through-flow model. The turbocharging system of the original engine was modified and the energy flow distribution between the diesel cycle and the Brayton cycle was optimized. Results show that the fuel economy of the diesel engine can be improved by 2.6% at high engine speed and 4.6% at low engine speed under engine full load operating conditions when equipped with the Brayton cycle WHR system. The influence of turbocharger parameters on the WHR engine performance was invesgated.     

Demonstrating Improved Fuel Economy Using Subsystem Specific Lubricants on a Modified Diesel Engine

Fuel economy performance in modern internal combustion engines is of increasing importance to lubricant formulators due to regulations targeting global greenhouse gas emissions. Engines typically employ a single lubricant, with a common sump, to service all components. As a result, base oil and additive selection for fuel economy performance is a compromise among competing demands for different engine subsystems. Opportunities for significant fuel economy improvement through targeted formulation of lubricants for specific engine subsystems are presented, with specific emphasis on segregating the lubricant supplies for the valve train and the power cylinder subsystems. A working prototype was developed in a lab environment by modifying a commercially available twin-cylinder diesel engine. Motored valve train and whole-engine fired test results were obtained and compared to model data. Fuel economy benefits were demonstrated using market representative heavy-duty diesel lubricants, including mineral oil and polyalphaolefin (PAO) blends. The fuel economy benefits of a dual-loop lubricant system are demonstrated through significant viscosity reduction in the power cylinder subsystem, achieving overall engine friction reductions of up to 8% for the investigated operating condition. Results suggest that additional gains may be realized through targeted base oil and additive formulation. Implications for incorporation in larger diesel engines are also considered.     

电控单体泵式柴油机的建模与仿真研究

基于柴油机缸内工作过程的数学模型，在MATLAB/SIMULINK环境下建立了一个涡轮增压发动机的仿真模型，详细描述了柴油机、增压器的热力学和动力学子模型。该模型主要用于研究电控单体泵式柴油机中的各种控制参数对性能的影响，也用于调整喷油正时的控制策略。以YC6112柴油机为仿真对象，给出了典型稳态过程的仿真结果。由于大部分采用非线性模型，该系统能很好的满足动态仿真的精度要求，也解决了准线性模型大量依赖试验和经验数据的问题。     

Method for evaluating the reliability of compressor impeller of turbocharger for vehicle application in plateau area

As turbocharging diesel engines for vehicle application are applied in plateau area, the environmental adaptability of engines has drawn more attention. For the environmental adaptability problem of turbocharging diesel engines for vehicle application, the present studies almost focus on the optimization of performance match between turbocharger and engine, and the reliability problem of turbocharger is almost ignored. The reliability problem of compressor impeller of turbocharger for vehicle application when diesel engines operate in plateau area is studied. Firstly, the rule that the rotational speed of turbocharger changes with the altitude height is presented, and the potential failure modes of compressor impeller are analyzed. Then, the failure behavior models of compressor impeller are built, and the reliability models of compressor impeller operating in plateau area are developed. Finally, the rule that the reliability of compressor impeller changes with the altitude height is studied, the measurements for improving the reliability of the compressor impellers of turbocharger operating in plateau area are given. The results indicate that when the operating speed of diesel engine is certain, the rotational speed of turbocharger increases with the increase of altitude height, and the failure risk of compressor impeller with the failure modes of hub fatigue and blade resonance increases. The reliability of compressor impeller decreases with the increase of altitude height, and it also decreases as the increase of number of the mission profile cycle of engine. The method proposed can not only be used to evaluating the reliability of compressor impeller when diesel engines operate in plateau area but also be applied to direct the structural optimization of compressor impeller.     

A model and the methodology for determining wear particle generation rate and filter efficiency in a diesel engine using ferrography

A mathematical model was developed that describes the wear particle concentration as a function of time in a diesel engine. This model contains engine and lubrication system parameters that determine the concentration of wear particles in the engine sump. These variables are the oil system volume, oil flow rate, particle generation rate, filtering efficiency and the initial particle concentration. The model was employed to study the wear particle concentrations in the sump and the mass of particles in the filter for the Cummins VT-903 diesel engine. In addition, the model was used to develop a testing methodology for determining wear particle generation rates and filter efficiencies from used oil analysis. This testing methodology uses ferrography together with computer programs to yield accurate statistical information on the data as curve fitted to the model. The test set-up incorporated a remote-controlled sampling system that enabled the accurate and periodic taking of oil samples over an engine test approximately 5 h in duration.

Results of this research indicate that equilibrium wear particle concentrations increase with an increase in engine speed and load. The wear particle generation rate and filter efficiency as determined by the test methodology were found to decrease with an increase in engine speed and load. After oil and filter changes, the wear particle generation rate and filter efficiency continually increased with cumulative engine time up to approximately 11 h. The test methods used to obtain the results above were found to be repeatable to within ±15% and could conceivably be employed to determine wear parameters on other diesel engines as well as the effects that other engine variables such as lubricants, oil temperature, coolant temperature and engine components have on the wear parameters.     

Model-based diagnosis of large diesel engines based on angular speed variations of the crankshaft

This work aims at monitoring large diesel engines by analyzing the crankshaft angular speed variations. It focuses on a powerful 20-cylinder diesel engine with crankshaft natural frequencies within the operating speed range. First, the angular speed variations are modeled at the crankshaft free end. This includes modeling both the crankshaft dynamical behavior and the excitation torques. As the engine is very large, the first crankshaft torsional modes are in the low frequency range. A model with the assumption of a flexible crankshaft is required. The excitation torques depend on the in-cylinder pressure curve. The latter is modeled with a phenomenological model. Mechanical and combustion parameters of the model are optimized with the help of actual data. Then, an automated diagnosis based on an artificially intelligent system is proposed. Neural networks are used for pattern recognition of the angular speed waveforms in normal and faulty conditions. Reference patterns required in the training phase are computed with the model, calibrated using a small number of actual measurements. Promising results are obtained. An experimental fuel leakage fault is successfully diagnosed, including detection and localization of the faulty cylinder, as well as the approximation of the fault severity.     

A study on in-cylinder flow field of a 125cc motorcycle engine at low engine speeds

The in-cylinder flow characteristics of a four-stroke, four-valve, pent-roof small engine of motorcycle at engine speeds from 2000 rpm to 4000 rpm were studied using computational fluid dynamics (CFD). The aim of this study was to investigate the in-cylinder flow characteristics of small engines, including tumble, swirl, turbulent kinetic energy (TKE), angular momentum, in-cylinder air mass, turbulent velocity, turbulent length scale, and air flow pattern (in both intake and compression strokes) under motoring conditions. The engine geometry was created using SolidWorks, then was exported and analyzed using CONVERGE, a commercial CFD method. Grid independence analysis was carried out for this small engine and the turbulence model was observed using the renormalized group (RNG) k-ɛ model. The pressure boundary conditions were used to define the fluid pressure at the intake and exhaust of the port. The results showed that the increase in the engine speed caused the swirl flow in the small engine to be irregularly shaped. The swirl flow had a tendency to be stable and almost constant in the beginning of the compression stroke and increased at the end of compression stroke. However, the increase of in engine speed had no significant effect on the increase in tumble ratio, especially during the intake stroke. There was an increase in tumble ratio due to the increase in engine speed at the end of compression stroke, but only a marginal increase. The increase in engine speed had no significant effect on the increase in angular momentum, TKE, or turbulent velocity from the early intake stroke until the middle of the intake stroke. However, the angular momentum increased due to the increase in engine speed from the middle of the intake stroke to the end of compression stroke, and the angular momentum achieved the biggest increase when the engine speed rose from 3000 to 4000 rpm by 10 % at the end of the intake stroke. The increase in engine speed caused an increase of TKE and turbulent velocity from the middle of intake stroke until the end of compression stroke. Moreover, the biggest increase of TKE and turbulent velocity occurred when the engine speed rose from 3000 to 4000 rpm at the middle of intake stroke around 50 % and 25 %, respectively. Turbulent length scales appeared to be insensitive to increasing engine speed, especially in the intake stroke until 490 °CA. From that point, the value of the turbulent length scale increased as engine speed increased. The biggest increase in the turbulent length scales occurred when the intake valve was almost closed (around 20 %) and the engine speed was within two specific ranges (2000 to 3000 rpm and 3000 to 4000 rpm). Regarding the effect of engine speed, there were no significant effects upon the accumulated air mass in the small engine. The increase in engine speed caused an increase of turbulence in the combustion chamber during the late stages of the compression stroke. The increase in turbulence enhanced the mixing of air and fuel and made the mixture more homogeneous. Moreover, the increase in turbulence directly increased the flame propagation speed. Further research is recommended using a new design with several types of intake ports as well as combinations of different intake ports and some type of piston face, so that changes in air flow characteristics in small engines can be analyzed. Finally, this study is expected to help decrease the number of experiments necessary to obtain optimized systems in small engines.

     

Phenomenological combustion modeling of a direct injection diesel engine with in-cylinder flow effects

A cycle simulation program is developed and its predictions are compared with the test bed measurements of a direct injection (DI) diesel engine. It is based on the mass and energy conservation equations with phenomenological models for diesel combustion. Two modeling approaches for combustion have been tested; a multi-zone model by Hiroyasu et al (1976) and the other one coupled with an in-cylinder flow model. The results of the two combustion models are compared with the measured imep, pressure trace and NOx and soot emissions over a range of the engine loads and speeds. A parametric study is performed for the fuel injection timing and pressure, the swirl ratio, and the squish area. The calculation results agree with the measured data, and with intuitive understanding of the general operating characteristics of a DI diesel engine.     

回收船舶柴油机余热的有机朗肯循环系统热力学性能比较分析

利用有机朗肯循环(ORC)系统对某型号船舶柴油机(最大持续功率为996 kW)的余热进行回收,以系统净输出功为指标,对比分析5种不同结构形式的ORC系统的热力学性能,结果表明:回收柴油机排烟余热的基础ORC系统最大净输出功达49.83 kW;增设回热器进一步回收膨胀机出口工质废热后,系统最大净输出功达54.84 kW;...