The fuel consumption and performance of the Internal Combustion (IC) engine is improved by adopting concepts of an adiabatic engine. An experimental investigation for different load conditions is carried out on a water-cooled, constant-speed, twin-cylinder diesel engine. This research is intended to emphasize energy balance and emission characteristic for standard uncoated base engine and adiabatic engine. The inner walls of diesel engine combustion chamber are thermally insulated by a top coat of Metco 204NS yttria-stabilized zirconia (Y2O3ZrO2) powder (YSZ) of a thickness of 350 mm using plasma spray coating technology. The same combustion chamber is also coated with thermal barrier coating (TBC) bond coats of AMDRY 962 Nickle chromium aluminum yttria of thickness of 150 mm. The NiCrAlY powder specially designed to produce coating’s resistance to hot corrosion. The combination of this ceramic material produces excellent high-temperature thermal barrier coating (TBC) resistant to thermal cycling stresses and strains. The engine valves, engine heads, and engine pistons were thermal barrier ceramic coated and computerized experimental results were compared to the base engine. Experimental results justified TBC…

Fuel economy is becoming one of the key parameter as it does not only account for the profitability of commercial vehicle owner but also has impact on environment. Fuel economy gets affected from several parameters of engine such as Peak firing pressure, reduction in parasitic losses, volumetric efficiency and thermal efficiency. Compression ratio is one of key design criteria which affects most of the above mentioned parameters, which not only improve fuel efficiency but also results in improvement of emission levels.This paper evaluates the optimization of Compression ratio and study its effect on Engine performance.The parameters investigated in this paper include combustion bowl volume in Piston and Cylinder head gasket thickness as these are major contributing factors affecting clearance volume and in turn the compression ratio of engine. Based on the calculation results, an optimum Compression Ratio for the engine is selected. Further Engine testing carried out with selected Compression ratios and parameters such as Fuel efficiency, In-cylinder pressure, and Brake thermal efficiency and Ignition delay were compared.

The control and design optimization of a Free Piston Engine Generator (FPEG) has been found to be difficult as each independent variable changes the piston dynamics with respect to time. These dynamics, in turn, alter the generator and engine response to other governing variables. As a result, the FPEG system requires an energy balance control algorithm such that the cumulative energy delivered by the engine is equal to the cumulative energy taken by the generator for stable operation. The main objective of this control algorithm is to match the power generated by the engine to the power demanded by the generator. In a conventional crankshaft engine, this energy balance control is similar to the use of a governor and a flywheel to control the rotational speed. In general, if the generator consumes more energy in a cycle than the engine provides, the system moves towards a stall. If the generator consumes less energy, then the effective stroke, compression ratio and maximum translator velocity must rise steadily from cycle-to-cycle until the heat transfer losses stop the…

At gasoline direct injection, light-duty engines operated with homogeneous, stoichiometric combustion mode, particulate emissions are mainly formed in diffusion flames that result from prior fuel wall wetting. Besides the piston, liner, and intake valves, the injector tip acts as a main particulate source when fuel is adhered to it during an injection. Hence, this injector tip fuel wetting process and influences on this process need to be analyzed and understood to reduce engine-out particulate emissions. The present work analyzes the injector tip wetting process in an experimental way with a high-speed and high-resolution measurement system at an optically accessible pressure chamber. The performed measurements reveal that injector tip wetting can occur during the complete injection event by different mechanisms. Large spray cone angles at start and at end of injection or distortions of the spray result in direct contact of the fuel spray with the step-hole wall. Additionally, fuel accumulates during an injection in the step-hole volume and discharges onto the injector tip surface subsequently. Furthermore, a poor primary breakup at end of injection can…

This paper describes the design of a novel pneumatic gear shifting system to replace the existing gear stick manual shifting system for ease of the driver while shifting gears. The aim of this work is to have a semi-automatic shifting (pneumatic shifting) removing the need for the driver clutch operation. The system consists of a solenoid valve, CO2 gas-pressurized cylinder, double-acting cylinder, and single-acting cylinder. On basis of the signal received the gear needs to be changed, the shifter opens or closes a magnetic valve assembly. The solenoid valve allows the compressed air into the piston that comes from a pressurized cylinder, in order to create the effect of shifting gears. The pedal shifter and buttons are used to shift the gears. The pedal shifter was designed by using a 3-D printing technique using PLA material. The microcontroller used is ATMEGA-328 in this system. There are three switches, one for upshift, downshift, and clutch respectively. An algorithm has been created in a microcontroller for a sequential gearbox of CBR 600RR. The system has been so…

By looking current scenario, engine development lead time was reducing day by day to enter early in the competitive market and to compete as early as possible. During initial engine development phase, it was very important to know how engine operating temperatures were affecting to piston pack and related system. Conventionally temp plug method was used to capture the piston temperature, but it was time consuming, much costly, for every test condition, new temp plug pistons required, if unfortunately, any hot shutdown happened during the test, again full test needs to be restarted with new set of temp plug pistons and many more limitations. So, for Cummins engine we used Telemetry technique to measure the piston temperature ONLINE and in real time.Piston telemetry enables the telemetric transfer of piston data from internal reciprocating and rotating components. The pistons had wireless telemetry to send real time steady state and transient data from within engines. The piston telemetry data transfer devices used to meet the stringent demands of harsh operating environments. Piston telemetry transmitters can be run…

Improvement of performance and emission of future internal combustion engine for passenger cars is mandatory during the transition period toward their substitution with electric propulsion systems. In middle time, direct injection spark ignition (DISI) engines could offer a good compromise between fuel economy and exhaust emissions. However, abnormal combustion and particularly knock and super-knock are some of the most important obstacles to the improvement of SI engines efficiency. Although knock has been studied for many years and its basic characteristics are clear, phenomena involved in its occurrence are very complex and are still worth of investigation. In particular, the definition of an absolute knock intensity and the precise determination of the knock onset are arduous and many indexes and methodologies has been proposed.In this work, most used methods for knock onset detection from in- cylinder pressure signal have been considered. Moreover, knock intensity has been evaluated by means of two common indexes. High speed imaging has been carried out in the combustion chamber of a high performance DISI engine provided with an optical window in…

Accurate and fast positioning of large aircraft component is of great importance for Automated Alignment System. The Ball joint is a widely-used mechanical device connecting the aircraft component and positioners. However, there are some shortcomings for the device in man-machine engineering, such as the entry state of the ball-head still needs to be confirmed by the workers and then switched to the locking state manually. To solve above problems, a new positioning mechanism is present in this paper, which consists of a ball-head and a ball-socket. The new device is equipped with a monocular vision system, in which a calibrated industrial camera is used to collect the images of the ball-head. And then, the 3-D coordinate of the ball-head center is calculated by a designed algorithm, guiding the positioner to capture the ball-head. Once the ball-head gets into the ball-socket, the pneumatic system will drive the pistons to move to the specified location. Meanwhile, the amount of compression of a set of springs has changed, so the steel balls are compelled to compress, contact or…