The work demonstrating a novel approach to the optimization of crankshaft design
for heavy-duty commercial vehicle engines, specifically targeting non-automotive
applications with elevated power ratings. The research focuses on a 6-cylinder,
5.6-litre diesel engine, originally rated at 160 kVA and upgraded to 200 kVA,
where the challenge was to enhance the crank-train system’s robustness within
existing packaging constraints.
By fundamentally altering the crankshaft’s geometry and structural parameters,
the new design achieves higher load-bearing capacity while inherently mitigating
torsional vibrations, thereby eliminating the need for viscous dampers
traditionally used in place of rubber dampers. Advanced simulation tools,
notably AVL Excite, employed to iterate and evaluate the balance between
crankshaft balance ratio, weight, and torsional behavior. The optimized design
then validated through both simulation and physical vibration trials, with
sixth-order angular displacement maintained within prescribed limits.
Further refinement of the simulation model achieved by optimizing the torsional
stiffness of the ring gear to ensure strong correlation with physical
measurements. This work demonstrates an effective alternative to viscous dampers
and provides a pathway for future crankshaft design in high-power commercial
engines.