Browse Topic: Engine lubrication systems

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Guide to Engine Lubrication System MonitoringAIR1828D (Current)5/15/2026
This SAE Aerospace Information Report (AIR) provides information and guidance for the selection and use of technologies and methods for lubrication system monitoring of gas turbine aircraft engines. This AIR describes technologies and methods covering oil system performance monitoring, oil debris monitoring, and oil condition monitoring. Both on-aircraft and off-aircraft applications are presented. A higher-level view of lubrication system monitoring as part of an overall engine monitoring system (EMS) is discussed in ARP1587. The scope of this document is limited to those lubrication system monitoring, inspection, and analysis methods and devices that can be considered appropriate for health monitoring and routine maintenance. This AIR is intended to be used as a technical guide. It is not intended to be used as a legal document or standard.
E-32 Aerospace Propulsion Systems Health Management
Oil Systems for Helicopter PowerplantsAIR4281A (Current)3/13/2026
Turbine engines installed in helicopters require a highly sophisticated oil system to fulfill two primary tasks: Cooling/oil supply Lubrication of rotating components (bearings, shafts, gears, etc.) While lubrication is an engine internal operation, depending on the engine oil system configuration, cooling and oil supply may require more or less design activity on the aircraft side of the engine/airframe interface for proper engine function. The necessity for engine cooling and oil supply provisions on the airframe can lead to interface problems because the helicopter manufacturer can influence engine related functions due to the design of corresponding oil system components.
S-12 Powered Lift Propulsion Committee
Exploring the Effects of Oil Cooler Deletion on Tractor Engine Operation2026-26-05471/16/2026
An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the engine's operational reliability. This research offers valuable guidance for optimizing hardware selection and cost- effective design strategies in off-highway vehicles. Cost reduction remains a significant challenge for engine manufacturers, particularly for off-highway application vehicles, as they strive to ensure robust performance without compromising reliability.
Gupta, Deepak, Kumar, Pankaj, Singh, Manjinder, Singh, Gagandeep, Kumar, Munish, Singh, Harpreet, Singh, Maninder
Komatsu augments intelligent machine control in new excavator25TOFHP12_0612/1/2025
Komatsu has launched a new excavator, the PC220LCi-12, that features its latest intelligent machine control technology. IMC 3.0 incorporates automation enhancements and a reported “construction-industry first” technology - factory-integrated 3D boundary control - designed to boost operator productivity. The intelligent machine, displayed previously at Bauma 2025 in Munich, Germany, has many of the same features as the new PC220LC-12 excavator, including a cab that is 28% larger, with 30% more legroom and 50% improved visibility compared to the PC210LC-11 model. Other advantages the new machines offer are up to a 20% increase in fuel efficiency thanks to a new electrohydraulic system and 129-kW (173-hp) next-generation engine, and up to a 20% reduction in maintenance costs due to longer replacement intervals for hydraulic oil and oil filters and longer cleaning intervals for the particulate filter.
Gehm, Ryan
Three-Dimensional CFD Analysis of a Flat Engine Lubrication System2025-01-02156/16/2025
This study presents a comprehensive, transient, 3-D Computational Fluid Dynamics (CFD) model of a multi-cylinder flat engine's lubrication system, simulated using Simerics-MP+. Engine lubrication system is crucial for reducing friction, cooling, and cleaning engine components. Understanding its performance is essential for optimal engine operation. The model was applied to the lubrication system of a 4-cylinder, reciprocating internal combustion engine. The computational domain includes the positive displacement gerotor pump, pressure regulation valve, bearings, piston cooling jets, oil cooler, oil filter, and other relevant components. The gerotor pump and gallery bearings were modeled using real 3-D geometries without any assumptions. Bearing deformation and orbiting due to force imbalance were prescribed in the simulations. The simulation was conducted at 5000 rpm of engine speed. The simulated flow pressure distributions closely matched experimental data.
Shiyi, Pan, Nan, Zhang, Jing, Liu, Mingliang, Liu, Wei, Wang
Glossary of Terms Related to Fluid Filters and Filter TestingJ1124_202505 (Current)5/3/2025
Over the years during which fluid filtration systems have been developing, many terms have come into use for descriptions of characteristics of filter media, filter assemblies, test methods, and test materials. Inevitably, some terms have been applied loosely so that the same term may have different meaning to different people, or in different frames of reference. Recognizing the need for clearly defined terms, which can have only one meaning for all persons in all circumstances, so that documents dealing with standard methods of evaluation of filters will have only one interpretation, the Filter Test Methods Subcommittee of the SAE Engine Committee has compiled this Glossary of related terms. No attempt has been made to produce an all-inclusive document, containing definitions of all terms related to all types of fluid filters. Instead, the Glossary is confined to the terms likely to be encountered in relation to filters for lubricating oil and fuels. At the same time, we have recognized that some terms are common to all types of fluid filters and have been careful to avoid conflict with the definitions published by other standardizing groups. If not identical, the definitions of these terms are at least worded to convey an identical meaning, hopefully in fewer, simpler, or more precise words. We hope that this effort will be effective in helping to eliminate the ambiguities which have resulted from imprecise use of terminology and filtration. This Glossary is referenced in the SAE filter test methods documents. Terms used in those documents are intended to have the definitions shown by this Glossary, and no other. As new terms and their definitions become associated with the science of filtration and are relevant to the documents prepared by this subcommittee, revisions to the Glossary will be made, either by issuance of addenda or by revision and republication of the entire document.
Filter Test Methods Standards Committee
Aerated Oil in the Rotating Channel03-18-03-00184/24/2025
In this article we examine the behavior of oil in the lubrication channel between the main bearing and the connecting rod bearing in the crankshaft of an internal combustion engine. The requirement for high service life and proper operation of these bearings, while minimizing input power of the lubrication system, lead to the need to understand the function of these structural parts in detail. To simulate and visualize this process, an experimental device was created. The device allows the experimenters to change individual parameters such as rotation speed, oil pressure, oil temperature, and aeration, while simultaneously visualizing the process with the help of a special rotating camera. These parameters are then obtained by image processing. In this way, the following influences are investigated here: at oil temperatures of 30, 50, and 80°C, relative oil pressures of 1, 2, 3, and 4 bar, at undissolved air in the oil of 5 and 10 vol% and crankshaft station speeds from 0 to 6000 1/min. The work is inspired by previously known publications by other authors. Their results were obtained mainly using computational methods. In the case of experiments, the authors used indirect methods of measurement using pressures and flows. Therefore, this work has a great contribution in the experimental area. The results of the experiments show the influence of the tested parameters on the gradual limitation of the oil flow through the channel. At a relative oil pressure of 1 bar and a crankshaft speed of 6000 1/min, the pressure even drops to 0 bar, and the oil flow through the channel collapses. The results of image processing show not only the area of the channel filled with oil, but also the distance of the beginning and end of the air bubble from the beginning of the channel.
Rychtar, Vaclav
A 3-D CFD Performance Simulation of a Feedback Controlled Variable Displacement Vane Pump2025-01-81794/1/2025
Variable Displacement Vane Pumps (VDVPs) are widely used in lubrication systems for engines, transmissions, and electric drive units. This study presents a Computational Fluid Dynamics (CFD) analysis of a rotational VDVP, coupled with an Oil Control Valve (OCV), to establish a feedback loop that regulates the eccentricity of the cam ring, and consequently, the pump’s outlet flow rate. In previous studies, Simerics-MP+ has been successfully utilized to model the VDVP without considering the OCV’s effect. The OCV consists of a solenoid valve coupled with a spring-loaded spool valve. Due to the absence of the actual valve geometry, the valve behavior in the CFD model is represented by a 2-D table that correlates the control chamber flow rate with both the supply and control pressures. The eccentricity of the cam ring is determined through an iterative process, balancing fluid torques from the vane chamber pressures and control chamber pressure, along with the spring torque. Simulation results for the solenoid valve at 0% and 100% Pulse Width Modulation (PWM) conditions align well with the test data, staying within acceptable limits. This simulation methodology can be extended to model other VDVP applications.
Khatri, Rachit Rajesh, Liu, Yuchan, Pasunurthi, Shyam Sundar, Ahmed, Rayhan, Stallmann, John, Yang, Bo, Huang, Yuli, Sivaji, Rangarajan, Scheffler, David
A Comparative Study on the Working Efficiency of Journal Bearing Employing Different Micro-Textures04-18-02-00112/19/2025
This study proposed the different micro-textures of the SC (square cylinder), SWS (square wedge shape), HS (hemispherical shape), and CR (cylindrical round) to improve the working efficiency of the journal bearing. A hydrodynamic lubrication model of the journal bearing under the impact of the changing dynamic loads is established to analyze the performance of micro-textures. The maximum oil film pressure and minimum frictional force in the journal bearing are selected as two evaluation indices. Some outstanding research results show that all the SC, SWS, HS, and CR added on the bearing surface improved the working efficiency of the journal bearing better than without the micro-textures. Moreover, the HS also improved the working efficiency of the journal bearing better than other structures of SC, SWS, and CR. To optimize the working efficiency of the journal bearing using HS, the dimension ltex and depth htex of HS should be selected and designed in a range of 3.6 < ltex ≤ 3.9 mm and 7.5 ≤ htex ≤ 10 μm, especially at ltex = 3.6 mm and htex = 10 μm. Research results not only provide a detailed assessment of the lubrication efficiency of different micro-textures but also find a new structure of HS with their optimal parameters to further improve the working efficiency of the journal bearings.
Song, Fengxiang, Nguyen, Vanliem, Liu, Yaxi
A Step towards Pragmatic Carbon Emission Reduction in Heavy Duty Diesel Vehicles through Differentiated Diesel and Green Combo Lubricants2024-01-430311/5/2024
With all the environmental concern of diesel fuelled vehicle, it is a challenge to phase out them completely specifically from Heavy duty application. Most pragmatic solution lies in solutions which improves the fuel economy and reduce the carbon emission of existing diesel fuelled vehicle fleet and retain the economic feasibility offered by present diesel fuelled vehicle fleets. With implementation of Bharat Stage IV (BS VI) emission norms across country from April 2020, supply of BS VI complaint diesel fuel started and BS VI complaint vehicles with upgraded engine technologies and after treatment devices started to come which made present vehicle fleets heterogeneous with substantive number of BS IV vehicle. Beside improvement of engine technologies, existing BS IV vehicle fleet performance can be enhanced through improved fuel and lubricants solutions. The present research work is a step towards improving the fuel economy of existing BS IV diesel vehicles through the intervention of differentiated diesel fuel and dedicated state of the art lubricants combinations. Developed through modification & up-gradation of BS VI diesel fuel, Differentiated Diesel fuel is having excellent injector cleaning properties, improved combustion, low soot formation etc which intern improve the combustion result in fuel economy improvement and reduce carbon emissions. Further, efforts were made to comprehensively review the lubricant requirement of vehicle. Green combo lubricants have been designed & developed with state-of-the-art lubricants combination comprising engine oil, transmission oil and axle oil which reduce the friction from engine and drivelines and results in further fuel economy benefit. To evaluate the actual fuel economy improvement and emission reduction credentials, comprehensive field trials of Differentiated Diesel and Green Combo lubricants were undertaken in fleet of heavy-duty diesel buses deputed at state transport. State transport was selected due to availability of BS IV complaint diesel fuelled buses of varied vintage from 50,000 km to 200,000 km and nearby vicinity to have better field trial supervision. Field trials were designed in such a way that combined effect of Differentiated Diesel and Green Combo Lubricants and then effect of Green Combo lubricants alone can be evaluated. Fleet of buses were charged with Green Combo lubricants after proper flushing and put new engine oil filter. After charging the Green Combo lubricants, buses were fuelled with Differentiated Diesel and sent to their routine routes for actual running for evaluating the combined effect of differentiated diesel and Green Combo lubricants for initial field trials and buses covered in the range of 25,000 km to 40,000 km each. Afterwards, field trial buses were fuelled with normal BS VI diesel and completed the field trials for evaluation the effect of Green Combo lubricants only. Used engine oil samples and idle emissions through portable emission measurement system as per field trial protocol were taken during the field trials. 120,000 km field trials were successfully completed, and it demonstrated that Differentiated Diesel and Green Combo Lubricant together improved the fuel economy by 8% - 9% and emission reduction in Carbon Dioxide (CO2), Carbon Monoxide (CO), Nitrogen Oxides (NOx), and Total Hydrocarbon (THC) are 4.5%, 10%, 4% and 5 % respectively. Green Combo lubricants alone improved the fuel economy by 4% - 5%. Used engine oil analysis confirmed the satisfactory performance of Green Combo lubricants during field trials. Based on theoretical assessment of implementation of this combination together at throughout state transport leads to saving of ~ 350 Kilolitre's (KL) Diesel annually and thus ~ 925 Tonne CO2 annually which shows the immense potential of saving the precious diesel fuel and reduced the carbon emission.
Mishra, Sumit Kumar, Singh, Punit Kumar, Chakradhar, Maya, Seth, Sarita, Singh, Sauhard, Arora, Ajay, Harinarain, Ajay Kumar, Maheshwari, Mukul
Improving Reliability of 2 Wheelers Using Predictive Diagnostics2023-01-183610/24/2023
The On-Board Diagnostics (OBD) system can detect problems with the vehicle’s engine, transmission, and emissions control systems to generate error codes that can pinpoint the source of the problem. However, there are several wear and tear parts (air filter, oil filter, batteries, engine oil, belt/chain, clutch, gear tooth) that are not diagnosed but replaced often or periodically in motorcycles/ power sports applications. Traditionally there is a lack of availability of in-field and on-board assistive tools to diagnose vehicle health for 2wheelers. An alert system that informs the riders about health and remaining useful life of their motorcycle can help schedule part replacements, ensuring they are always trip-ready and have a stress-free ownership and service experience. This information can also aid in the correct assessment during warranty claims. With the increase of onboard sensors on vehicles, there has been a notable increase in the availability of condition-monitoring data such as vibration, temperature, pressure, voltage, and other electrical and mechanical parameters. The connectivity device on the motorcycle can transmit this onboard real time data to the cloud for analysis to derive the information of useful life of these components. This paper presents an edge-plus-cloud architecture with part of the algorithm in the Engine Control Unit (ECU) and final processing done on the cloud. Various sensor signals and other vehicle operating parameters are collected and processed using a combination of Machine learning, Fast Fourier Transform, Regression models and other data analytical algorithms. Based on the analysis, information transmitted back from cloud/ Edge device to Vehicle Instrument cluster/ Mobile App/ Web UI to inform rider before the failure has occurred, along with real time data of the remaining useful life of these components.
Vijaykumar, Srikanth, Sabu, Abhijith, PRADHAN, DEBAYAN, Shrivardhankar, Yash
Lubricant Performance and Reliability of Ammonia Fueled Internal Combustion Engines2023-32-01049/29/2023
Using ammonia as a fuel has been experimented since the nineteenth century in different types of ground and air vehicles but it was never able to replace fossil- based hydrocarbon fuels at scale. Nevertheless, this concept has gained a new momentum following recent policies to significantly reduce greenhouse gas emissions in fuel intensive sectors such as power generation and transportation. Following the strategy of the International Maritime Organization (IMO) to reduce the carbon intensity from international shipping by at least 50 percent by 2050, the implementation of zero-carbon fuels on a tank to wake basis, such as ammonia, is being strongly considered by the maritime ecosystem. Additionally, initiatives from other industries have emerged recently, demonstrating a broader interest in ammonia fuel for sustainable operations such as heavy duty and off-road applications. Whereas its toxicity and handling protocols fuel numerous discussions and working groups, ammonia reactivity and possible interactions with the combustion engine also rise concerns. In particular, the adequation between ammonia combustion and engine lubrication system could be of paramount importance to ensure reliable engine operations over the lifetime of the equipment. This study investigates the impact of ammonia combustion on engine lubrication based on specific engine tests and lubricant ageing procedures. A 4 stroke Diesel internal combustion engine was modified to operate in dual-fuel mode with ammonia on steady state operating points. Different engine lubricants were tested, and oil samples were taken over extended periods of time to evaluate engine behavior in combination with final engine inspections. Analytical techniques and laboratory performance tests were performed to study the evolution of lubricant properties under ammonia-powered engine operations. Results provide novel insights on ammonia engine reliability and compatibility of engine oil composition with ammonia.
Obrecht, Nicolas, Griffaton, Bruno, Rappo, Maria
Design Optimization Methods for Forced Lubrication System Used in Automotive Transmissions02-16-04-00257/18/2023
Lubrication has been a major area of interest in engineering. Especially in vehicle transmissions, lubrication plays a very crucial role because gears and bearings are constantly subjected to heavy loads. Proper lubrication is essential for maintaining system performance and ensuring endurance life. Insufficient lubrication can lead to excessive wear, increased friction, and eventually, failures in the transmission components. However, excess lubrication can result in power losses due to the resistance offered by the excessive lubricant. Therefore, achieving effective lubrication using optimized lubrication system design is vital for ensuring the longevity and efficiency of the transmission system. Majorly, two types of lubrication methods are used in transmissions: splash lubrication and forced lubrication. This article focuses on forced lubrication, where the lubrication system actively delivers the required flow of lubricant to specific locations within the transmission. Pump outflow, orifice diameters, and channel dimensions are a few of the critical design parameters of the forced lubrication system. This article presents two design optimization methods: one using ANSYS DX (3D) and the other using GT-Suite (1D) tool. In the 3D method, ANSYS Fluent is used for CFD (computational fluid dynamics) simulations and subsequently ANSYS DesignXplorer (DX) is leveraged for design optimization. Predictions from CFD simulations are validated against physical test data and show good agreement (>90% match for flow rate). GT-SUITE is used in the 1D method, which is validated with predictions from 3D CFD method. The optimized designs obtained from both methods are effective in achieving the desired flow rate distribution, demonstrating their reliability. The ANSYS DX method provides an advantage in terms of reduced overall turnaround time (50% less) for the optimization. On the other hand, co-simulation (CFD+1D) approach can prove beneficial if it is required to perform minor routing changes on the lube system layout.
Shamini, R., Jadhav, Priyanka, Deshpande, Shrikrishna, Chavan, Sagar
In Situ Assessment of Oil Quality Sensor Performance in Engine Lubricant Flow04-17-02-00077/13/2023
Assessing the functional quality of an engine lubricant through real-time sensing could pave the way for development of comprehensive engine health monitoring systems. In this study, a permittivity-based, commercial off-the-shelf (COTS) oil quality sensor was implemented in the lubricant flow of a diesel engine after detailed evaluation on a benchtop test facility. The sensor was mounted on the oil filter housing of the engine in the post-filter oil flow, and its implementation required no modifications to the engine block. Simultaneously, the lubricant flow was visualized by incorporating a novel test cell in the oil flow path. Both the sensor assembly and the flow visualization cell were fully characterized on the benchtop facility prior to implementation on the engine. In these experiments, fresh and used samples of the engine’s recommended oil were tested, and the sensor’s oil quality measurements showed noticeable differences between the engine and benchtop studies, a feature attributable to the observed presence of aeration intrinsic to the engine oil flow. These results prove that the adaptation of permittivity-based sensors for effective real-time engine lubricant quality monitoring will require comparative assessment of oil quality measurements in aerated and nonaerated flow fields.
Schepner, Cameron, Smith, Adam, Schafer, David, Anilkumar, Amrutur
MPR Micropitting Test MethodARP6991 (Current)6/1/2023
This method is designed to evaluate the micropitting performance of currently available and future aviation turbine oil formulations. Drawing on previously performed tests documented in AIR6989, the method comprises of three rings rotating against a rotating central roller configuration using the standard, commercially available PCS Instruments Micropitting Rig (MPR). A test profile has been developed between industry and academia that relies on standard, commercially available test specimens.
E-34 Propulsion Lubricants Committee
Modelling of Polymer Suction Tube through Simulations2023-28-13075/25/2023
The oil is picked up from the oil sump and transferred to the pump housing via a suction tube at the desired rate. A strainer is fitted to the end of the suction tube to filter out any dust or debris that may be present. Steel tubes and wire mesh strainers are used to make the current suction tube. Suction tube design shouldn't have an excessively long inlet suction that would make the suction tube's pressure insufficient to suck the oil from sump. Additionally, the pump's suction side air leak or low temperature-induced low oil viscosity prevents the pump from priming. This paper will examine suction tube design analysis and compared the development of steel and polymer suction tube concepts. The lightweight polymer suction tube with respect to fluid dynamics aspects is compared with conventional wire mesh. Extreme temperature analysis of polymer suction tubes will be compared to baseline steel tubes for suction flow, the impact of mesh area, pressure drop, and temperature parameters, and findings will be presented. The flow performance of polymer suction tubes was found to be substantially above that of steel wire mesh suction tubes. Due to the decreased opening area of an all-polymer suction tube, the average pressure drop is larger, and pressure decreases in the suction tube have an impact on the pump's filling speed. Compared to steel suction tubes, polymer suction tubes are lighter and cheaper, easier to manufacture, need fewer parts, and have higher reliability.
NALE, ANIKET ARUN, Maurya, Rohit K, Soma, Nagaraju, Mohammed, Zubair
Hybrid Electric Vehicle Engine Operation and Engine Oil Degradation: A Research Approach04-17-01-00015/4/2023
Hybrid electric vehicles (xHEV) are a critical enabler to fulfil the most recent CO2 and fuel economy requirements in key markets like North America, China, and Europe [1, 2]. Different levels of hybridization exist; the main differentiator is the power of the electric system and battery capacity. Increased electrical power enables the vehicle to run more often in electric mode and recuperate energy from braking, which enhances the saving potential [3]. Mild (MHEV) and plug-in hybrid vehicles (PHEV) impose different duty cycles on the engine compared to a conventional powertrain, potentially altering the degradation mechanisms of the lubricant, and challenging the basis on which the lubricant should be condemned [4]. The biggest concerns are water and fuel dilution [5], which promote corrosion and can form emulsions [6]. This may result in so-called white sludge formation (a thick and creamy emulsion) which can deposit inside the engine on colder surfaces, potentially blocking pipes and breather hoses [6]. White sludge deposits on the oil filler cap can become visible to the vehicle operator and may be a reason for concern. Many original equipment manufacturers (OEMs), and their customers, need advice in defining the important oil parameters for the oil to be fit for purpose. If oil and additive companies are to respond to these challenges, an increased awareness and understanding of oil degradation in modern vehicle platforms is required. In this work, we have investigated the operating conditions in different hybrid vehicles and their impact on the engine oil. First, a chassis dynamometer (CD dyno) test program was conducted to understand how three different concepts influence engine operation, specifically the engine oil temperature and the number of stop/start events. Second, engine dyno testing was designed to replicate a worst-case scenario, extrapolating some of the observations from CD testing, to investigate the effect of an extreme drive cycle on the engine oil degradation and contamination. Finally, an analysis of the chemical and physical properties of these engine test drain oils, and the resulting impact on wear protection and engine cleanliness, was undertaken to understand the risks associated with worst-case scenario xHEV operation.
Growney, David, Joedicke, Arndt, Williams, Megan, Robin, Mathew, Mainwaring, Robert, Davies, Mark
New 2.0 L Inline 4-Cylinder Gasoline Direct Injection Engine2023-01-04004/11/2023
Honda has developed a new hybrid system targeting the C and D segments that aims for the latest environmental performance, high fuel economy, and enhanced acceleration feeling in driving. The new engine to be applied to this new hybrid system has been developed with the goal of expanding the high thermal efficiency range, realizing the latest environmental performance, and high quietness. The new engine has adopted the Atkinson cycle and cooled exhaust gas recirculation (EGR) carried over from the previous model [1], and employed an in-cylinder direct fuel injection system with fuel injection pressure of 35 MPa. The combustion chamber and ports have been newly designed to match the fuel system changes. By realizing high-speed combustion, the engine realized a high compression ratio with the mechanical compression ratio of 13.9. In addition, emission during engine start was suppressed by split injection and optimization of the injection timing to comply with the Super Ultra-Low Emission Vehicle (SULEV) regulations. The higher compression ratio and high-speed combustion increased the engine noise and vibration, and the high-pressure direct fuel injection system has generated larger operating noise than the conventional fuel injection system. Therefore, the crankshaft, cylinder block, oil pan, chain case, and other parts of the new engine have been newly designed to provide enhanced noise and vibration (NV) performance. Furthermore, the conventional acoustic insulators and Theta Fiber Cells (TFC) insulators that have sound absorption effects inside the engine room have been also redesigned. This achieved engine radiation noise equivalent to the previous model, and also contributed to enhancement of the vehicle quietness.
Yamaguchi, Ryo, Egawa, Takeshi, Ushio, Nobuhiro, Kasajima, Yuya, Kondo, Toshifumi, Ikeya, Kenichiro
Investigation Of Variable Displacement Oil Pump and Its Influence on Fuel Economy for a 1.5 L, 3 Cylinder Diesel Engine2023-01-04654/11/2023
The Introduction of Corporate Average Fuel Economy (henceforth will be addressed as CAFE) regulations demand suitable technological upgrades to meet the significant increase in targets of vehicle fleet fuel economy. Engine Downsizing and Friction Reduction measures help in getting one step closer to the target. In a Conventional Oil Pump, the pump discharge flow and pressure are a direct function of operating speed. There is no control over lubricant flow which results in increased power and fuel consumption due to its unnecessary pumping characteristics irrespective of the actual engine demand. This paper discusses the introduction of a variable displacement oil pump (henceforth will be addressed as VDOP) that was adapted to a 1.5-liter 3 Cylinder Diesel Engine. This approach helps the system to reduce parasitic losses as the oil flow is regulated based on the mechanical needs of the engine. The flow is regulated with help of a solenoid valve which receives input from the ECU. The engine Oil Pump has a major role in enabling the transfer of lubricant to all moving engine components. The demand majorly depends on engine performance characteristics, bearing clearances, operating temperatures, and wear behavior of engine components. The paper explains the boundary conditions for VDOP design packaging, challenges in system adaptation, impact on engine lubrication circuit, performance, and friction reduction benefit.
Sithick basha, Abubakker, vinaya murthy, Vijayendra, Rengaraj, Chandrasekaran, Dharan R, Bharani, Kumar PS, Adm Venkatesh
Investigation of Solenoid-Controlled Piston Cooling Jet Benefits for a 1.5l, 3 Cylinder Tcic Diesel Engine2023-01-02304/11/2023
The fuel economy of the internal combustion engine becomes progressively critical, especially with the stringent standards set by the government. To meet the government norms such as CAFE (Corporate Fuel Average Economy), different technologies are being explored and implemented in internal combustion engines. Several technologies such as variable oil pump, map controlled PCJ (Piston Cooling Jet), variable or switchable water pump & ball bearing turbocharger etc. This study investigates the effectiveness of implementing map-controlled PCJ implemented for a 1.5-litre 3-cylinder diesel engine. PCJ’s are major consumers of oil flow and map-controlled PCJ is used by many OEM’s e.g., Ford EcoSport to reduce the oil pump flow. In map-controlled PCJ, the oil to the PCJ is controlled using a solenoid valve. The solenoid valve can be completely variable or ON/OFF type. In our application, the ON/OFF type solenoid value is used to regulate the oil flow to PCJ. Conventionally, the oil to the PCJ is supplied at all operating conditions of the engine, even when the piston temperature is within the material acceptable limit. This adds to the parasitic loss of the internal combustion engine, due to the high friction power consumed by the oil pump to meet the oil flow rate requirement. Using the solenoid-controlled PCJ along with Variable Displacement Oil Pump (VDOP), the flow to the PCJ can be shut down at certain operating conditions such as high speed, and low load conditions. Using the VDOP, the total oil flow rate can be reduced whenever there is no flow to the PCJ, this will help to reduce engine friction load & improve the overall fuel economy. The objective of the paper is to show the systemic approach, design modifications & challenges involved in the implementation of the map controlled PCJ. The final engine with the map-controlled PCJ along with VDOP is evaluated in the NEDC (New European Driving Cycle) drive cycle to understand the benefits & an overall fuel economy of 1 – 2 % was observed. Results are discussed in detail, which have enabled to take required decision on implementation of Map Controlled PCJ in the specific engine application.
vinaya murthy, Vijayendra, Sithick basha, Abubakker, Dharan R, Bharani, Rengaraj, Chandrasekaran, VIGNESH, A. C.
Optimization Design and Performance Verification of the Second Generation Single Motor Plug-in Hybrid System (EDU) of SAIC Motor Vehicle Company2023-01-04464/11/2023
SEAT Department of SAIC Motor Vehicle Company starts innovatively applying the single motor and P2.5 configuration scheme from EDU G2(Electric Drive Unit Generation 2), which consists of six engine gears and four motor gears. EDU G2 is very compact and adaptable through the coupling design. Gear coupling make the engine and motor coordination limited, so as to the high efficiency zone of the engine and the high efficiency zone of the motor cannot match in some working conditions, which affect the performance of the vehicle. Therefore, SEAT developed the second generation of single-motor plug-in hybrid system EDU G2 Plus EDU G2(Electric Drive Unit Generation 2 Plus), which realized the decoupling design of 5 engine gears and 2 motor gears, so that the power output of engine and motor is freely. With excellent power and economic performance, the vehicle has been well received by customers. The article mainly describes the system design and development on the themes of motor performance improvement, system efficiency improvement and NVH optimization. SEAT takes the lead in adopting the hair-pin motor winding scheme, compared with the ordinary circular motor, the slot full rate of the Hairpin motor is increased by 20%~25%. The number of motor windings is increased from 2 layers to 5 layers, the maximum efficiency and comprehensive efficiency of the motor are significantly improved. Compared with the EDU G2, EDU G2 Plus has been optimized in some mechanical paths, including application of low roll resistance bearings, matching and selection of lubricating oil, optimization of cooling and lubrication system. In NVH performance , through motor body optimization and gear modification, the motor gear is reduced from 41 to 27 order, providing a more comfortable experience for the vehicle. The innovative scheme design of this paper provides a reference for the design and mass production of hybrid P2.5 configuration Plug-in Hybrid System.
ge, Hailong, Zhao, Zhiguo
Power Cylinder Oil Consumption: Methods of MeasurementsJ2796_202304 (Current)4/4/2023
This document describes the major techniques for measuring oil consumption. It does not cover all the sub-variations that might be used to make this measurement.
Piston and Ring Standards Committee
ENGINE OIL PUMP PERFORMANCE AND DURABILITY TEST PROCEDURESUSCAR46 (Current)3/23/2023
SAE/USCAR-46 defines test methods and outputs for engine oil pump bench testing. Performance and durability testing are the primary focus of this standard. This is written to specifically address testing of electronically controlled variable displacement pumps but can be adapted to mechanically controlled pumps and other pump technologies as needed. This standard outlines critical inputs and outputs in order to perform the testing and report results, but does not specifically set the acceptance standards or pass/fail criteria. Acceptance criteria must be set by the customer.
USCAR
RING, RETAINING, EXTERNAL, INTERLOCKINGAS90708C (Current)3/20/2023
E-25 General Standards for Aerospace and Propulsion Systems
Heavy-Duty Vehicle Cooling Test ProceduresJ1393_202302 (Current)2/6/2023
The purpose of this SAE Recommended Practice is to establish a testing procedure to determine the performance capability of heavy-duty vehicle cooling systems to meet Original Equipment Manufacturer or end user thermal specifications to ensure long term reliable vehicle operations. The recommendations from the present document are intended for heavy-duty vehicles including, but not limited to, on- and off-highway trucks, buses, cranes, drill rigs, construction, forestry, and agricultural machines.
Cooling Systems Standards Committee
Turbine Drive Shaft ConnectionARP721 (Current)1/20/2023
This ARP applies to turbine engines that are to be used in helicopters. It provides the engine designer guide lines in achieving a satisfactory turbine engine drive shaft connection.
S-12 Powered Lift Propulsion Committee
Contaminants for Testing Air Brake Components and Auxiliary Pneumatic Devices - Truck and BusJ2024_202211 (Current)11/22/2022
This SAE Information Report establishes a minimum level of uniform recipes for contaminants which may be used when durability testing pneumatic components to obtain additional information on how a device may perform under more true-to-life operating conditions. This type of contamination testing, however, is not meant to replace the type of performance testing described in SAE J1409 and SAE J1410. Durability testing in the presence of contamination will yield results more reflective of actual in-service field conditions and provide an additional evaluation of pneumatic devices. While the contaminant supply rate and other test criteria of the device being tested must be set by the device manufacturer or user, the items covered in this document will be:
Truck and Bus Brake Supply and Control Components Committee
Challenges and Strategies to Reduce Oil Dilution for BS6 Diesel Application2022-28-032410/5/2022
Fuel entry into oil sump dilutes oil and affects its tribological properties, leading to increased engine wear and failure. Higher oil levels can also lead to uncontrolled combustion and unintended vehicle acceleration. In modern BS6 Diesel engines equipped with Diesel Particulate Filters (DPF), the late post injections are a major source of oil dilution. Other sources of fuel in oil dilution are pump failure and improper geometric sealing of moving parts. In vehicles with NOx Storage Catalyst (NSC) installed, the rich mode would also have a high share in the oil dilution. The SAE paper addresses ways to reduce fuel entry rate from post-injections without compromising the DPF performance. The accumulated soot is regenerated at high exhaust temperature. The high exhaust temperature is achieved by introducing late post injections (PoI1) continuously throughout the regeneration duration (approximately 20 to 30 mins). These late post injections are timed closer to exhaust valve opening during the expansion stroke. Due to the engine geometry, injected quantity may reach the cylinder liner quench and Diesel may drop into the oil sump. Over the life of the vehicle, with subsequent regeneration events, the oil in the sump gets diluted with the Diesel fuel. Hence, the oil dilution must be well within acceptable limits based on the application.
Chaudhari, Kuldeepak, Aravind, Akshay Seethanadi, V, Lakshmi, Wolter, Marcus
NVH Refinement using Structural Optimization for Low-Powered Tractor2022-28-010910/5/2022
NVH is very important topic in development of a vehicle. Legislative requirements for driver ear level, the comparison to competitor vehicles in terms of noise and vibration as well as sound quality set very challenging targets. High noise at Driver Ear Level (DEL) and tactile vibrations of tractor is the major cause of exhaustion to the operator. With growing competition there is need for the tractor manufacturers to control noise and vibration levels. Recognizing the corrective measures to reduce the noise and vibration has a greater impact in increasing the efficiency of the product and operator comfort. Objective of this paper is to control vehicle level noise and vibrations using vehicle level structure modifications. It includes airborne and structure borne NVH study on a tractor by measuring sound pressure and vibration levels at vehicle level. Single cylinder engine was mounted on light weight structure to meet the power and torque requirements in the tractor. Also, there is no passive vibration control system in Indian tractors. Due to this the problem of noise and vibration arises. There is need to isolate the engine and transmission vibration from the body with rubber mounts. In this way appreciable reduction in noise and vibration can be achieved. Tests were performed to distinguish the root cause of unwanted noise and vibrations produced during operation of the tractor. Abnormality in exterior noise was observed. These problems were rectified by structural alterations. Addition of acoustic side shields and oil sump cladding was beneficial for exterior noise. Vibration was found higher at all tactile locations. Addition of frame stiffeners improved vibrations significantly at all tactile locations. Attachment point stiffness also increased. Addition of masses on steering wheel, driver seat locations.
MENON, VINEETH VENUGOPAL, THAKUR, SUNIL, Kunde, Sagar, Wagh, Sachin
Experimental Investigation of the Effect of Gasoline Fuel on Engine Performance, NOx reduction, and Engine Wear of a 38.8L Military Heavy Duty CIDI Diesel Engine Applying EGR2022-01-10278/30/2022
Rapidly depleting oil reserves and strict pollution regulations have made it necessary to find a substitute for diesel fuel. In the context of the multi-fuel strategy program, gasoline has improved the fuel availability for both combat and commercial highway vehicles with diesel engines. This study examines the effect of gasoline fuel on the engine wear, performance, and emission of a military, heavy-duty, supercharged diesel engine. In a CIDI diesel engine, the use of Gasoline has been considered to be significantly sustainable with engine performance and reduced pollutants. For this research a military heavy-duty, 38.8 L, 585kW, diesel engine, the EGR technique was used for gasoline and diesel fuels. Furthermore, the impact of nanoparticles on NOx emissions was also explored. NOx emission reduces in diesel engines by using the EGR technique. Two test fuels were tested in their trials for a total of 100 hours of engine endurance assessment. After every 20 hours of engine operation, 100 mL of lube oil was extracted from the oil sump and tested for elemental analysis. Ferrography and atomic absorption spectroscopy have been used to measure the composition of metal wear debris. It was used to evaluate the metal wear on the exposed cylinder liner. A new engine part was used to perform durability tests for test fuels. For gasoline-powered engines, metal wear was estimated to be 10 to 12 percent higher than for diesel-powered engines. Gasoline fuel's engine performance was 4.5% lower than diesel fuel. When the engine was running on Gasoline, NOx emissions were reduced by 28%, and nanoparticle emissions were also reduced.
Pandey, Anand Kumar, Nandgaonkar, Milankumar, Sonawane, C, Kumbhar, Vishal, Varghese, Anil
Test Method for Determining Power Consumption of Cooling Fan Drive SystemsJ1342_202208 (Current)8/26/2022
The techniques outlined in this SAE Recommended Practice were developed as part of an overall program for determining and evaluating fuel consumption of heavy-duty trucks and buses, but it is applicable to off highway vehicles as well. It is recommended that the specific operating conditions be carefully reviewed on the basis of actual installation data. Cooling requirements are affected by all heat exchangers that are cooled by the fan drive system. These may include radiators, condensers, charge air coolers, oil coolers, and others. Because of the variation in size, shape, configuration, and mountings available in cooling fans and fan drive systems, specific test devices have not been included. Using known power/speed relationships for a given fan, this procedure can be used to calculate the fan drive system’s power consumption for cooling systems using the types of drives listed below. This power consumption may then be used in determining engine net power per SAE J1349. For more fan power/speed relationships, refer to SAE J1339.
Cooling Systems Standards Committee
Products of TomorrowTBMG-466577/1/2022
This column presents technologies that have applications in commercial areas, possibly creating the products of tomorrow. To learn more about each technology, see the contact information provided for that innovation.
Helicopter Engine/Airframe Interface Document and ChecklistARP1507B (Current)6/27/2022
This SAE Aerospace Recommended Practice (ARP) provides a guide for the preparation of a helicopter engine/airframe interface document and checklist. This document and checklist should identify the information needed by the engine manufacturer and the aircraft manufacturer to integrate the engine design with the aircraft design and either provide this information or give reference to where this information is located. The intent is to assure that the engine manufacturer and the airframe manufacturer identify and make provision for this information so it can be easily accessible to either manufacturer as needed in the development stages of an engine-airframe integration project. A related document, SAE Aerospace Information Report AIR6181, provides guidance on creating an interface control document (ICD) which addresses a subset of the aircraft-engine interface information concerning the physical and functional interfaces of the electronic engine control system (EECS) with the aircraft systems. This would include signal interfaces, digital data busses and integrated functionality with the aircraft electronic systems and avionics displays. The engine/airframe interface document should reference this EECS ICD rather than duplicate its information. Similarly, as information is documented in the engine installation manual or engine installation drawings, the engine/airframe interface document should make references to the engine installation manual or engine installation drawings, rather than duplicate the information. Typically, the engine/airframe interface document will be the initial document in the project to capture the interface information which can then transition to referenced information as the engine installation manual, EECS ICD, and engine installation drawings are developed.
S-12 Powered Lift Propulsion Committee
Fuel and Oil HosesJ30_202205 (Current)5/2/2022
This SAE Standard covers fuel, oil, or emission hose for use in coupled and uncoupled applications, for use with gasoline, oil, diesel fuel, lubrication oil, or the vapors present in either the fuel system or in the crankcase of internal combustion engines in mobile or stationary applications. This standard covers the hose portion only. If assembly/coupling is required, that is to be agreed to between the customer and assembler, along with the specific requirements.
Non-Hydraulic Hose Committee
Expendable Jet Engine Oil TankTBMG-458085/1/2022
Zulu Pods Miami, FL 786-445-0540
CFD Topology and Shape Optimization of Twin Ports in Integrated Exhaust Manifolds2022-01-07853/29/2022
The optimization of the exhaust port shape for best mass flow is an excellent opportunity to improve fuel economy, emissions, and knock sensitivity of internal combustion engines (ICE). This is valid for many different types of combustion systems including gasoline, alcohols, alternative fuels such as compressed natural gas (CNG) or hydrogen, and e-fuels. Nowadays, so-called cylinder-head integrated exhaust manifolds (IEM) guide the exhaust gas from the combustion chamber to the turbocharger. This specific design requires lots of strong bends and turnings of the exhaust ports in very narrow space, since they need to be guided through a labyrinth of bolts, water cores, and oil passages. In fact, this challenges the avoidance of increased pressure drops, reduced mass flow rates, and deterioration of port flow efficiencies. The optimization of the individual port by computational fluid dynamics (CFD) is a proper means to minimize or even eliminate these drawbacks. Meanwhile, there are several powerful optimization methods for three-dimensional flows on the market. In this paper, a combined strategy of CFD topology and shape optimization is presented. This method has been applied to several Ford four-valve engine designs with either twin (Siamese) exhaust ports as well as single ports within two separate IEMs. CFD optimizations have been done for various valve lifts resulting in improved mass flow rates by up to 14 % and an improved mass flow balance between the twin exhaust ports. New flow cross-sections such as L-, F-, and T-shapes have been identified. At the end, an initial design of flow-optimized ports has been generated including body-fitted water jacket surfaces. This allows the designer to already start with an optimized exhaust port design. The new workflow is highly efficient, reduces development time, improves result quality, and may reduce the number of expensive prototypes as well as time-consuming test-rig measurements.
Hopf, Anselm
Prediction and Experimental Verification for Oil Transport Volume around Three-Piece Type Oil Control Ring Affecting Lubricating Oil Consumption2022-01-05223/29/2022
Reducing of lubricant oil consumption (LOC) remains a major issue for internal-combustion engines. Especially in recent years, in order to comply with Particular Number (PN) regulations and lower oil viscosity to reduce friction loss, need to reduce the LOC has increased. Controlling the upward oil flow, that passes the piston and piston rings, is effective in reducing the LOC. In addition, oil control ring (OCR) has significant effect on upward oil flow. Therefore, development of a high-precision prediction method of oil behavior around the OCR is important for prediction of LOC. So, the model of Three-piece type oil control ring (3POCR) motion within the OCR groove and the model of oil behavior around the 3POCR were developed using the computer aided engineering (CAE) method in this paper. These models calculate in detail the upward oil outflow to the 3rd land from the OCR groove, which is based on the relation between the OCR motion and the gas pressure as well as the inertial force of oil. Since factors that greatly affect the prediction accuracy are the gas pressure around the OCR and the OCR motion, these were measured and verified in the actual engine. Furthermore, oil behavior observation using in-cylinder visualization engine, and oil film thickness measurement using optical fiber were conducted for experimental verification of the oil behavior model around the 3POCR. As a result, qualitative tendency of calculated results and measured results showed good agreement. Also, comparison in two different OCR specification, the similarly tendency was obtained. Therefore, the effectiveness of the developed prediction model was confirmed.
Mochizuki, Kazuya, Sasaki, Ryuichi, yazawa, Masaru, Iijima, Naoki, Usui, Miyuki
Review and Assessment of the Material’s Compatibility for Rubbers and Elastomers in Hydrogen Internal Combustion Engines2022-01-03313/29/2022
Hydrogen Internal Combustion Engines (H2-ICEs) are being investigated due to their minimal criteria pollutant and zero CO2 tailpipe emissions. However, oil filters and non-hot joint gaskets have rubber material that can be damaged and deteriorate due to direct or indirect exposure to the high temperature and high-pressure hydrogen in a H2-ICE. Thus, the effects on the properties of a rubber exposed to a hydrogen environment need to be reviewed. In this review paper, the transportation, chemical and mechanical properties of a rubber exposed directly or indirectly to high temperature and high-pressure hydrogen in a H2-ICE have been reviewed. The compatibility of rubber materials used in H2-ICE has been explored. The effects of high-pressure hydrogen on the transportation, chemical and mechanical properties of NBR and HNBR have been reviewed. It is concluded that when the hydrogen pressure is less than or equal to 10 MPa the hydrogen infiltration of rubber remains linearly proportional to the pressure of hydrogen and above 10 MPa hydrogen pressure the content of NBR and EPDM is nonlinearly proportional to hydrogen pressures. The addition of Carbon Black (CB) in the NBR composites increases the hydrogen infiltration and its content due to the trapping of hydrogen by Carbon Black (CB). This article also proposes safe temperature and pressure ranges in which the rubber can be used without leading to fracture and deterioration. At the end of this article, future work for the use of rubber in H2-ICE will be discussed.
Azeem, Naqash, Beatrice, Carlo, Vassallo, Alberto, Pesce, Francesco, Rossi, Riccardo, Khalid, Azka
3D CFD Simulation of Hydraulic Test of an Engine Coolant System2022-01-02073/29/2022
Designing an efficient vehicle coolant system depends on meeting target coolant flow rate to different components with minimum energy consumption by coolant pump. The flow resistance across different components and hoses dictates the flow supplied to that branch which can affect the effectiveness of the coolant system. Hydraulic tests are conducted to understand the system design for component flow delivery and pressure drops and assess necessary changes to better distribute the coolant flow from the pump. The current study highlights the ability of a complete 3D Computational Fluid Dynamics (CFD) simulation to effectively mimic a hydraulic test. The coolant circuit modeled in this simulation consists of an engine water-jacket, a thermostat valve, bypass valve, a coolant pump, a radiator, and flow path to certain auxiliary components like turbo charger, rear transmission oil cooler etc. A commercial CFD software, Simerics-MP+®, is used to simulate the hydraulic test for two different positions of the poppet valve of the thermostat, viz. a closed position and an 50% opening, at different speeds of the engine. In the CFD model, the complete geometrical details of water-jacket, thermostat, and pump are considered. The remaining components are approximated as pipes with flow resistance models to account for flow and pressure drop at different engine speeds. Firstly, the standalone pump performance is validated in the operating regime of interest, followed by the calibration of the resistance models for the simplified components. At the end, complete system level 3D simulations are conducted and validated for the above mentioned two positions of the poppet valve. The flow distribution and pressure drop across different components show good comparison with the hydraulic test data within 7% error band.
Ballani, Abhishek, Bhagat, Meghraj, Srinivasan, Chiranth, Pasunurthi, ShyamSundar, Maiti, Dipak, Zhang, Yi, Motin, Abdul
Design of Cylinder Block for Horizontal K Configuration2022-01-06313/29/2022
Cylinder block is the bulkiest component in engine. It undergoes severe thermal and mechanical loads. Also, cylinder block is multifunctional as it includes positioning of coolant and lubrication circuit, location of coolant and oil pumps, locating cylinder head to form closed combustion chamber, locating mounting points of engine, mounting of alternator, starting motor, and AC compressors. Hence, the cylinder block design should be the strong and robust enough to handle the forces induced by combustion. Taking this requirement as the base, cylinder block is designed for Horizontal K type configuration. In this research, the mounting points of cylinder block are decided based on the imbalance forces for the configuration and from the gas pressure forces. Rigid body dynamics approach is used for locating the mounting points of engine. Topology optimization is carried out to know the location of coolant circuit. As the engine is subjected to heavy thermo-mechanical loads, initially transient structural analysis is performed on the block to determine the mechanical stress and deformation and subsequently, thermo-mechanical analysis is performed to check for thermal deformation and stresses and also to know the maximum temperature reached. Topology optimization, rigid body dynamics, preload bolt analysis, MODAL analysis, transient structural and thermo-mechanical analysis are performed in ANSYS 2019 R3 software. The positioning of the mounting points are discussed in this paper. Along with this, structural and thermal analysis are performed on the final cylinder block to understand its strength and to know whether the designed block is suitable for the engine working conditions.
Kadge, Rushiraj
Research on Clearance of Multi-Arc Combined Gerotor Pump Based on CFD2022-01-06333/29/2022
Due to the advantages of compact structure, stable operation, and low cost, the gerotor pumps are widely used in the cooling and lubricating system of automobiles. The multi-arc combined gerotor pump is a gerotor pump with a special profile. In this paper, the calculation method of the inner and outer rotor profile of the above-mentioned pump is introduced, and its meshing characteristics are analyzed. In general, three kinds of clearances would be processed to ensure the operation of the pump, named as tip clearance, axial clearance, and radial clearance. These clearances have a great impact on the performance of the pump so that it is important to design them. In response to this problem, this paper established a flow field characteristics model of the multi-arc combined gerotor pump based on computational fluid dynamics (CFD) method, and the effectiveness of the model is then verified through experiments. The influence of the three types of clearances on the flow field characteristics of the pump is analyzed. The results show that reducing the values of the three types of clearance will increase the average outlet flow of the pump, but will inevitably increase the flow rate irregularity at the same time in most cases, among which the impact of the tip clearance is the most significant. Besides, as the clearance value reduces, the amount of flow rate increase will gradually decrease. The conclusions of this paper provide data support for the selection of the clearance value of the pump under different working conditions.
jiang, Yue, Li, Min, Wang, Yonggang, Zhen, Ran, Shangguan, Wen-Bin
Experimental and Simulation Analysis of 1.3 Litre Water Cooled Engine Lubrication Circuit2022-01-01823/29/2022
To meet stringent reduction in exhaust emission and improving internal combustion engine fuel efficiency, have forced the designer to optimize auxiliary systems like lubrication and cooling. This paper describes the experimental and simulation verification of a 1.3 litre water cooled engine lubrication system. The lubrication circuit model is built in Ricardo Ignite software. The simulation model preparation steps using 3D-CAD model is explained in paper. Engine main bearing and connecting big-end bearing leakage maps are evaluated using Ricardo Valdyn software which is capable of simulation engine crank-train multi body dynamics along with bearing oil behavior. The pressure and flow distribution at various locations are predicted using simulation model. These simulation predictions are experimentally verified. It is observed acceptable correlation between simulation and experimental values. The same calibrated model is used for a case study where engine main oil gallery pressure for lower speed range is improved. Various options are studied for avoiding major modification in lubrication circuit mode. It is found that pipe attaching main oil gallery and gear-train uses benzo. The optimum benzo internal diameter is optimized and observed ~ 0.5 bar main oil gallery pressure improvement in low speed rages. The simulation model is verified experimentally and observed promising correlation. The intention of this work is to check feasibility of this technique for establishing good confidence and expertise in lubrication system developments.
Nain, Ajay
Design and Optimization of an SUV Engine Compartment Bottom Shield Based on Kriging Interpolation and Multi-Island Genetic Algorithm2022-01-01723/29/2022
Engine compartment thermal management can achieve energy saving and emission reduction. The structural design of the components in the engine compartment affects the thermal fluid flow performance, which in turn affects the thermal management performance. In this paper, based on the phenomenon that the surface of the parts in the engine compartment is abnormally high due to design defects of an SUV engine compartment bottom shield, the engine compartment is modeled and analyzed by CFD using the software STAR-CCM+. It is not conducive to the heat dissipation, so the bottom shield needs to be redesigned. To redesign the shape of the bottom shield, four dimensions and one coordinate value were selected as the design parameters, and the oil pan maximum surface temperature was selected as the optimization target. The Latin hypercube sampling method was used to sample the space uniformly, and the experimental design plan was constructed and simulated. The Kriging interpolation model was used to fit the oil pan maximum surface temperature; the multi-island genetic algorithm is used to optimize the simulation results to obtain the optimal design plan. It has been verified that under the same working conditions, the optimal design plan can reduce the oil pan maximum surface temperature by about 7°C, and the bottom shield surface temperature near the high-temperature exhaust pipe can be reduced by about 10°C, and the heat flow in the compartment can flow out smoothly, which eliminates the phenomenon of heat recirculation in the compartment caused by the design defect of the bottom shield.
Liu, Yong, Shi, Xiuyong, Zheng, Teng, Liu, Qiang, Ni, Jimin
Optimal Analysis of Layout Parameters of SUV Engine Compartment Parts Based on Orthogonal Design2022-01-01843/29/2022
The layout of component in the engine compartment affects the fluid flow performance, thereby affects the thermal management performance. Based on the fluid flow performance in the engine compartment of an SUV, this paper proposes local optimization plans of the cooling module—moving downward the oil cooler and forward the intercooler, tilting an angle of the cooling module and shifting the fan. This paper took the fan center temperature as the optimization goal and set three levels for the four factors. It was found that the deviation of the fan has the most significant impact on fan center temperature among four factors. Then we discovered that the interaction between the factors has a significant impact on the air intake volume of the cooling module. Finally, the optimization plans were designed with the goal of increasing the air intake volume of the cooling module and the final optimal plan was determined as the oil cooler was moved down by 150mm, the cooling module was tilted to the left by 2°, the fan was shifted by 50mm to the center, and the intercooler was moved forward by 60mm. Compared with the original layout of the cooling module under the three working conditions, the scheme has optimized the center temperature of the fan by 13.5%, 15.7%, and 11.9%, and the air intake volume has been optimized by 13.0%, 13.2%, and 12.3%, respectively.
Zheng, Teng, Ni, Jimin, Liu, Yong, Shi, Xiuyong
CFD Numerical Simulation Aero-engine Air-Oil Separator2022-01-00273/8/2022
Engine oil systems drive and de-aerate air-oil solutions in a two-phase flow to provide an appropriate amount of oil lubrication and cooling. especially in aero-engine and starter-generator component and system. The oil lubrication systems combine three important functions of the Main Oil Pump (MOP) for lubrication and scavenging: the de-aeration and de-oiling of the air-oil mixture generated in the bearing and gearbox sumps and pumping the oil towards the tank. These are critical functions for the aero-engine and starter-generator. An aero-engine lubrication system along with an integrated pump and separation of gas-liquid mixture has been developed and characterized experimentally to increase Collins Aerospace Engine and Control Systems research and development productivity. This system has also improved engine and starter-generator reliability and system performance. The Collins Aerospace pump and separator system is specially designed to handle air-oil mixtures generated in aero-engine lubrication systems. To address this need, a Computational Fluid Dynamic (CFD) analysis of the pump and separation system that allows in-flight performance prediction is presented in this paper. This CFD model applies different flight conditions under various engine rotational speeds that change during each flight phase, bleed air flow rates, and gearbox rotational speeds all of which contribute to creating the variables that compromise subsystem design.
Ni, William W.
Friction Factor Evaluation of Replaceable-Element and Conventional Oil Filters in a Precision Benchtop Test Facility04-15-03-00123/3/2022
This study examined the friction factor of replaceable element and conventional oil filters in a diesel engine lubrication flow setting, simulated in a precision benchtop facility that was developed for this purpose. Using clean engine oils, pressure drop across the filters was measured as a function of oil temperature and flow rate in the test facility in the range of 100-220°F and 2.0-4.5 GPM typical of diesel engine lubricant flow. The experimental results show systematic differences in the behavior between conventional and replaceable element oil filters attributable to temperature-related permeability variation in the replaceable filter element.
Smith, Adam D., Anilkumar, Amrutur V.
Power Cylinder Blow-by: Blow-by MechanismsJ2797_202202 (Current)2/15/2022
This document covers the mechanisms associated with the power cylinder system which might affect blow-by. It will not discuss in detail the blow-by mechanisms from other systems or engine subsystems.
Piston and Ring Standards Committee
Fuel-Economy Performance Analysis with Exhaust Heat Recovery System on Gasoline Engine03-15-06-00452/8/2022
As the electrification and connectivity technologies penetrate the market, the opportunities for intelligent thermal management of the vehicles become more salient. When an exhaust gas heat recovery (EGHR) system is used to recover waste heat from gasoline engine exhaust, the thermal parameters of the exhaust gas vary greatly, and these influence the performance of the heat exchanger (HE) system. To improve the recovery of exhaust waste heat and its conversion to faster coolant warm-up and cabin heating performance effectively, the heat transfer evaluation and optimal performance analysis are conducted on different EGHR system designs with different exhaust thermal parameters. This study aims at analyzing the fuel economy benefit with state-of-the-art HE designs in the automotive industry for exhaust gas-to-oil and exhaust gas-to-coolant heat transfer. Both physical testing and virtual simulation helped us develop a method to take advantage of the exhaust gas heat. The test result indicates that with the integration of the exhaust gas-to-coolant and exhaust gas-to-oil HEs, the gasoline engine makes a 0.5% and 0.8% fuel efficiency improvement, respectively. More specifically, the Worldwide harmonized Light vehicles Test Cycles (WLTC) fuel consumption on the 1.0L engine can be reduced by 0.5% with the integration of exhaust gas to the coolant HE, which has a smart bypass control strategy upstream of the oil cooler. Also the implementation of exhaust gas-to-oil HEs leads to a WLTC fuel consumption reduction of 0.8%. HE design with bypass valve and valve-controlled oil cooler from the experiments proved to be the most efficient HE design among the four investigated designs. The proposed simulation-based performance and engine dynamometer (dyno) evaluation shed light on the importance of selecting bypass valve and valve-controlled oil cooler HEs and design-related improvements in fuel economy for practical applications in building intelligent thermal management for vehicles.
Kumar, Vivek, Dadam, Sumanth Reddy, Zhu, Di, Mehring, Jan
Thermal balance in internal combustion engine with gasoline2021-36-00252/4/2022
The automotive internal combustion engine is a thermal machine that, from the combustion of the fuel inside the combustion chamber, releases thermal energy for the engine operation and consequently the displacement of the vehicle. A considerable part of this thermal energy is lost and the way to detect this loss is through experimental testing and applying the thermal balance to the engine. This work aimed to perform a thermal balance of the Otto cycle engine involving the energy released due to the gasoline combustion process, power delivered from the engine shaft, energy rate rejected for the cooling system, energy rate rejected for the exhaust system and energy rate rejected to the environment in the form of heat and incomplete combustion. The experiment consisted of making a thermal balance of the engine running with gasoline from experimental data measured on the engine operating on a bench dynamometer varying load and rotation conditions. The results showed that, concerning the energy rate released in the gasoline combustion process, approximately 27% was converted to thermal efficiency (shaft power), 16% was dissipated to the cooling system, 29% was rejected to the exhaust system and approximately 32% was energy lost to the environment, incomplete combustion and lubrication system. This research is important because it correlates useful energy in an Otto cycle engine with the actual losses. This allows, based on the detected energy losses, an opportunity for a more detailed study to optimize and improve engine performance.
Santana, Claudio Marcio, Bortolaia, Luís Antônio, Siqueira, Luana Magalhães
Information Report for the Installation of Fluid Conductors and ConnectorsJ2593_202201 (Current)1/21/2022
This SAE Information Report provides general information for installing and tightening fluid conductors and connectors. Following these guidelines, with the consistent proper use of torque wrenches, tightening procedures, and correct torque levels, will result in diminishing leaks and improving service life by avoiding hose twisting, tube binding, false torque, and improper joint closures. Since many factors influence the pressure at which a hydraulic system will or will not perform satisfactorily, this report should not be used as a “standard” nor a “specification,” and the values shown should not be construed as “guaranteed” minimums, maximums, or absolutes. This document is an information report to help users by gathering available information from the various connector standards and publishing the information in one source for easy retrieval and applied common usage. This SAE Information Report is primarily intended for mobile/stationary industrial equipment applications. Aircraft, automotive, and aerospace applications were not considered during the preparation of this document. When assembly procedure and torque level discrepancies between this document and associated connector specifications occur, the current connector specifications shall take precedence.
Hydraulic Tube Fittings Committee
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