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Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS

Tafe Motors and Tractors Limited-Omprakash Yadav, Piyush Ranjan, Vishal kumar, Vasundhara Arde, Sanjay Aurora, Remesan Chirakkal
  • Technical Paper
  • 2019-28-2549
To be published on 2019-11-21 by SAE International in United States
Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS Remesan CB, Sanjay Aurora, Vasundhara V Arde, Vishal Kumar, Om Prakash Yadav, Piyush Ranjan Eicher Engines (A unit of TAFE Motors & Tractors Ltd.) Abstract Development trend in diesel engine is to achieve more power from same size of engine. With increase in brake mean effective pressure (BMEP), the peak firing pressure will also increase. The methodology to control the peak firing pressure on higher BMEP is the major challenge. We achieved better SFC with CPCB II emission targets on a constant speed engine. This study involves a systematic approach to optimize combustion parameters with a cost effective and robust inline Fuel Injection System. This paper deals with the strategies applied and experimental results for achieving the power density of 25kW/lit with Inline FIP by keeping lower Peak firing pressure. Various combustion parameters such as Combustion Bowl Geometry, selection of Turbocharger, Swirl, FIP, Nozzle configuration, EGR flow rate, EGR operation strategy, optimizing injection pressures, start of injection, end of…
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APPLICATION ORIENTED HYBRIDIZED DYNAMIC MODELS OF POWERTRAIN CONTROL FOR CONNECTED VEHICLES – A CASE STUDY ON TURBOCHARGER CONTROL

Continental Germany-Richard Kopold PhD
Continental India-Vivek Venkobarao
  • Technical Paper
  • 2019-28-2443
To be published on 2019-11-21 by SAE International in United States
In a connected vehicle environment, the engine drive cycles operate in synchronized and regulated manner. This requires smooth transitions for improved CO_2 footprint. To arrive at this, there is need for intelligent and faster airpath control at transients. Authors aim to model and control every actuator of a coupled system in a synchronized manner with faster dynamic response. The turbocharger control is vital and forms heart of the system; This demands accurate position prediction of VTG. Deriving a control law for turbocharger is challenging due to the hybridized nature of turbocharger models in engine management system. It becomes extremely critical to estimate accurately, the position of VTG without introduction of any sensing devices. The control engineer always need to solve the trade-off between the controller performance KPI’s – rise time, transient response, controllability, observability and capability – stability and dynamics response etc. Author propose a model which improve the performance and capability of VTG control. Author presents a novel technique to model VTG position. A neural network based supervised learning model is derived. The model…
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Parametric Calculation and Significance of Engine Dynamic Torque in Performance Benchmarking of a Vehicle

Mahindra Research Valley-Praveen Kumar Ramani, Bharathraj Jayaraman, Sangeetha Ramasamy Thiruppathi
  • Technical Paper
  • 2019-28-0028
To be published on 2019-10-11 by SAE International in United States
The automotive industries around the world is undergoing massive transformation towards identifying technological capabilities to improve vehicle performance. In this regard, the engine dynamic torque plays a crucial role in defining the transient performance and drivability of a vehicle. Moreover, the dynamic torque is used as a visualization parameter in performance prediction of a vehicle to set the right engineering targets and to assess the engine potential. Hence, an accurate measurement and prediction of the engine dynamic torque is required. However, there are very few methodologies available to measure the engine dynamic torque with reasonable accuracy and minimum efforts. The measurement of engine brake torque using a torque transducer is one of the potential methods. However, it requires a lot of effort and time to instrument the vehicle. It is also possible to back-calculate the engine torque based on fuel injection quantity and other known engine parameters. Though this calculation method is relatively easy, it is not an accurate method. Moreover, it would not be possible to extract engine information of benchmark vehicles. Since every…
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Turbocharger Thermal Transfer Model Initialization: Quasi-Adiabatic Map Calculation

Ecole Centrale De Nantes-Guillaume Goumy, Pierre Marty, Pascal Chesse, Nicolas Perrot, Rémi Dubouil, Georges Salameh
  • Technical Paper
  • 2019-24-0232
To be published on 2019-10-07 by SAE International in United States
To comply with the evermore stringent polluting emission regulation, such as Euro 6c and its new homologation WTLP cycle, the use of turbocharger has been widely adopted amongst modern IC Engines, either in Diesel or Gasoline ones. It has also leaded to a large variety of implementation as single / two stage(s) or even parallel functioning. In the meantime, car manufacturer intend to decrease development cost and time by using more and more simulation over experimental measurements. However usual turbocharger model have not followed this trend of modernity and are still map based from turbocharger manufacturer data. While the heating part of the standard cycle becomes a major issue and simulation accuracy is the keystone of the new development strategies , turbocharger models have not followed this trend of modernity. They are still map based from turbocharger manufacturer data, measured in hot conditions, as this is usually the only available entry data. To improve their accuracy, new turbocharger model needs to take into account the thermal transfer. Different models have been offered to solve this…
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Axial Flow Turbine Concept for Conventional and e-Turbocharging

Brunel University-Apostolos Pesyridis
Universita di Napoli Federico II-Alessandro Cappiello, Raffaele Tuccillo, Maria Cristina Cameretti
Published 2019-09-09 by SAE International in United States
Engine downsizing has established itself as one of the most successful strategies to reduce fuel consumption and pollutant emissions in the automotive field. To this regard, a major role is played by turbocharging, which allows an increase in engine power density, so reducing engine size and weight. However, the need for turbocharging imposes some issues to be solved. In the attempt of mitigating turbo lag and poor low-end torque, many solutions have been presented in the open literature so far, such as: low inertia turbine wheels and variable geometry turbines; or even more complex concepts such as twin turbo and electrically assisted turbochargers. None of them appears as definitive, though.As a possible way of reducing turbine rotor inertia, and so the turbo lag, also the change of turbine layout has been investigated, and it revealed itself to be a viable option, leading to the use of mixed-flow turbines. Only recently, the use of axial-flow turbines, with the aim of reducing rotor inertia, has been proposed as well.The current paper documents a case study involving the…
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Development and Application of a Quasi-3D Model for the Simulation of Radial Compressors of Turbochargers for Internal Combustion Engines

Politecnico di Milano-Gianluca Montenegro, Matteo Tamborski, Augusto Della Torre, Angelo Onorati, Andrea Marinoni
Università degli Studi di Genova-Silvia Marelli
Published 2019-09-09 by SAE International in United States
In this work the 3Dcell method, a quasi3D approach developed by the Internal Combustion Engine Group at Politecnico di Milano, has been extended and applied to the fluid dynamic simulation of turbocharging devices for internal combustion engines, focusing on the compressor side. The 3Dcell is based on a pseudo-staggered leapfrog method applied to the governing equation of a 1D problem arbitrarily oriented in space. The system of equations is solved referring to the relative system in the rotating zone, whereas the absolute reference system has been used elsewhere. The vaneless diffuser has been modelled resorting to the conservation of the angular momentum of the flow stream in the tangential direction, combined with the solution of the momentum equation in the radial direction. Source terms due to the presence of the centrifugal force field and its potential have been included both in the energy and momentum conservation equations to account for the interaction of the fluid with the moving blades. The model has been validated against measurements carried out on a steady state flow test bench…
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Experimental and Numerical Analysis of a Dual Fuel Operation of Turbocharged Engine at Mid-High Load

Univ. of Zagreb-Darko Kozarac, Mladen Bozic, Ante Vucetic, Josip Krajnovic, Momir Sjeric
Published 2019-09-09 by SAE International in United States
In the paper the operation of a turbocharged dual fuel engine at mid-high load is investigated on a single cylinder experimental engine complemented by a full 0D/1D simulation model that provides boundary conditions for the experiment and full engine system results. When duel fuel combustion mode is used on a turbocharged engine with the variable geometry turbocharger, the mid-high load operating points can be obtained with number of different combinations of intake pressure and excess air ratio. Besides the impact on combustion, the specific combination of intake pressure - excess air ratio has also impact on the exhaust back pressure caused by the turbocharger and consequently on the obtained brake efficiency. Additionally, the dual fuel combustion is influenced by natural gas mass fraction and start of injection of diesel fuel and the search for the optimal solution could be a challenging task. The method presented here enables the use of a single cylinder experimental engine in this search, while simultaneously taking into account the influences of the effects of a full engine system. The results…
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Inverted Brayton Cycle as an Option for Waste Energy Recovery in Turbocharged Diesel Engine

Universita degli Studi dell Aquila-Davide Di Battista, Roberto Cipollone, Roberto Carapellucci
  • Technical Paper
  • 2019-24-0060
Published 2019-09-09 by SAE International in United States
Energy recovery in reciprocating internal combustion engines (ICE) is one of the most investigated options for the reduction of fuel consumption and GHG emissions saving in the transportation sector. In fact, the energy wasted in ICE is greater than that converted in mechanical form. The contribution associated with the exhaust gases is almost one third of the fuel energy, calling for an urgent need to be recovered into mechanical form. An extensive literature is oriented toward this opportunity, strongly oriented to ORC (Organic Rankine Cycle)-based power units.From a thermodynamic point of view, one option, not extensively explored, is certainly represented by the Inverted Brayton Cycle (IBC) concept and by the corresponding components which make possible this recovery. IBC is a thermodynamic (exhaust) gas cycle which considers an expansion (made by a turbine under the ambient pressure), an isobaric cooling and a compression in a sequence which restores the pressure which is needed to evacuate the exhaust gases toward the atmosphere. Thanks to the expansion which decreases the pressure below the ambient pressure, mechanical work produced…
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Driving Cycle and Elasticity Manoeuvres Simulation of a Small SUV Featuring an Electrically Boosted 1.0 L Gasoline Engine

Politecnico di Torino-Alessandro Zanelli, Federico Millo
Röchling Automotive-Marco Barbolini
  • Technical Paper
  • 2019-24-0070
Published 2019-09-09 by SAE International in United States
In order to meet the CO2 emission reduction targets, downsizing coupled with turbocharging has been proven as an effective way in reducing CO2 emissions while maintaining and improving vehicle driveability. As the downsizing becomes widely exploited, the increased boost levels entail the exploration of dual stage boosting systems. In a context of increasing electrification, the usage of electrified boosting systems can be effective in the improvement of vehicle performances. The aim of this work is therefore to evaluate, through numerical simulation, the impact of different voltage (12 V or 48 V) electric superchargers (eSC) on an extremely downsized 1.0L engine on vehicle performance and fuel consumption over different transient manoeuvres. The virtual test rig employed for the analysis integrates a 1D CFD Fast Running Model (FRM) engine representative of a 1.0L state-of-the-art gasoline engine featuring an eSC in series with the main turbocharger, an electric network (12 V or 48 V), a six speed manual transmission and a vehicle representative of a B-SUV segment car. A preliminary assessment of the steady state performances of the…
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Inner-Insulated Turbocharger Technology to Reduce Emissions and Fuel Consumption from Modern Engines

BorgWarner Turbo Systems-Jürgen Werner
Ricardo UK Ltd-Joshua Dalby
Published 2019-09-09 by SAE International in United States
Reducing emissions from light duty vehicles is critical to meet current and future air quality targets. With more focus on real world emissions from light-duty vehicles, the interactions between engine and exhaust gas aftertreatment are critical. For modern engines, most emissions are generated during the warm-up phase following a cold start. For Diesel engines this is exaggerated due to colder exhaust temperatures and larger aftertreatment systems. The De-NOx aftertreatment can be particularly problematic. Engine manufacturers are required to take measures to address these temperature issues which often result in higher fuel consumption (retarding combustion, increasing engine load or reducing the Diesel air-fuel ratio).In this paper we consider an inner-insulated turbocharger as an alternative, passive technology which aims to reduce the exhaust heat losses between the engine and the aftertreatment. Firstly, the concept and design of the inner-insulated turbocharger is presented. A transient 3D CFD/FEM (Computation Fluid Dynamics/Finite Element Modelling) simulation is conducted and predicts that external heat losses will be reduced by 70% compared to a standard turbocharger, i.e. non-insulated turbocharger. A 1D modelling methodology…
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