Browse Topic: Valvetrains
To improve the fuel efficiency and satisfy the strict emission regulations, the development of internal combustion engine gets more complicated in both hardware and software perspectives, and the margins for durability and NVH quality become narrower, which could result in poor NVH robustness in harsh engine operating conditions. In this paper, we investigate experimentally the camshaft impact noise mechanism relating the valve train and timing chain forces to detailed motion of the camshaft and the chain tensioner. After the initial investigation of identifying the impact timings and specific engine operating points when the noise occurs, the camshaft orbital motion inside of the sliding bearing is measured and visualized with the proximity sensors with calibration after sensor mounting, in addition to the chain tensioner movements. It is shown that the impact noise occurs at the event of the abrupt change of camshaft orbital motion, which results from the combined resultant force of
The major area in which the automotive manufacturers are working is to produce high-performance vehicles with lighter weight, higher fuel economy and lower emissions. In this regard, hollow camshafts are widely used in modern diesel and gasoline engines due to their inherent advantages of less rotational inertia, less friction, less weight and better design flexibility. However, the dynamic loads of chain system, valve train and fuel injection pump (if applicable) makes it challenging to design over-head hollow camshafts with the required factor of safety (FOS). In the present work, high-fidelity FE model of a hollow camshaft assembly is simulated to evaluate the structural performance for assembly loads, valve train operating loads, fuel injection pump loads and chain system loads. The investigation is carried out in a high power-density (70 kW/lit) 4-cylinder in-line diesel engine. The camshaft is used for operating the intake valves which induce varying stresses in-line with the
A single-stage turbocharger turbine is developed with the objective of enabling a gasoline spark-ignition engine to operate under lean-burn conditions with an air-to-fuel ratio of λ=2 in the range of the Worldwide Harmonized Light-Duty Vehicles Test Cycle. For this purpose, extensive 1-D engine simulations are performed using a combination of a simple compressor and simple turbine model as well as a combination of the stock compressor and a simple turbine model. The results show that an isentropic turbine efficiency of more than 70% over a wide operating range is required for the desired engine operation - especially with regard to the low-end-torque. Based on the crank-angle-resolved engine simulation data, turbine requirements are determined. Their evaluation shows that an axial turbine is a reasonable alternative to conventional radial turbines for this application. Next, a preliminary axial turbine is designed using 1-D/2-D design approaches. Then, the corresponding performance map
In the present work, a system approach to the tribological optimization of passenger car engines is demonstrated. Experimental data and simulation results are presented to demonstrate the role of surface specifications, ring pack, and lubricant on the piston/bore tribology. The importance of in-design “pairing” of low-viscosity motor oils with the ring pack and the cylinder bore characteristics in order to achieve maximum reduction in GHG emissions and improvement in fuel economy without sacrificing the endurance is elucidated. Earlier motored friction data for two different gasoline engines - Ford Duratec and Mercedes Benz M133 - using motor oils of different viscosity grades are now rationalized using AVL EXCITE® piston/bore tribology simulations. The main difference between the engines was the cylinder bore surface: honed cast iron vs thermally sprayed, and the valve train type: direct-acting mechanical bucket (DAMB) vs roller finger follower (RFF). The simulation data show that
In this contribution, the mechanical torque transmission between the Electric Motor (EM) and the Internal Combustion Engine (ICE) of a P0 architecture hybrid power unit is analysed. In particular, the system is made up of a brand new, single-cylinder 480cc engine developed on the basis of the Ducati 959 Panigale V90 2-cylinders engine. The thermal engine is assisted by a custom electric motor (30 kW), powered by a Li-Ion battery pack. The Ducati 959 Panigale engine is chosen because of its high power-to-weight ratio, and for taking advantage of its V90 2-cylinders layout. In fact, the proposed hybridization process considers to remove the vertical engine head and to replace it by the electric motor directly engaged to the crankshaft using the original valvetrain transmission chain, thus achieving a very compact package. This solution could be suitable for many V-type engines and it aims to obtain a small hybrid power unit for possible motorcycle/small vehicle applications. The original
This SAE Aerospace Recommended Practice (ARP) discusses design philosophy, system and equipment requirements, installation environment and design considerations for military and commercial aircraft systems within the Air Transport Association (ATA) ATA 100 specification, Chapter 36, Pneumatic. This ATA system/chapter covers equipment used to deliver compressed air from a power source to connecting points for other systems such as air conditioning, pressurization, ice protection, cross-engine starting, air turbine motors, air driven hydraulic pumps, on board oxygen generating systems (OBOGS), on board inert gas generating systems (OBIGGS), and other pneumatic demands. The engine bleed air system includes components for preconditioning the compressed air (temperature, pressure or flow regulation), ducting to distribute high or low pressure air to the using systems, and sensors/instruments to indicate temperature and pressure levels within the system. The engine bleed air system may
This study experimentally investigates the impact of Miller cycle strategies on the combustion process, emissions, and thermal efficiency in heavy-duty diesel engines. The experiments were conducted at constant engine speed, load, and engine-out NOx (1160 rev/min, 1.76 MPa net IMEP, 4.5 g/kWh) on a single cylinder research engine equipped with a fully-flexible hydraulic valve train system. Early Intake Valve Closing (EIVC) and Late Intake Valve Closing (LIVC) timing strategies were compared to a conventional intake valve profile. While the decrease in effective compression ratio associated with the use of Miller valve profiles was symmetric around bottom dead center, the decrease in volumetric efficiency (VE) was not. EIVC profiles were more effective at reducing VE than LIVC profiles. Despite this difference, EIVC and LIVC profiles with comparable VE decrease resulted in similar changes in combustion and emissions characteristics. Miller cycle operation at constant intake pressure
We have proposed the engine featuring a new compressive combustion principle based on pulsed supermulti-jets colliding through a focusing process in which the jets are injected from the chamber walls to the chamber center. This principle has the potential for achieving relatively silent high compression around the chamber center because autoignition occurs far from the chamber walls and also for stabilizing ignition due to this plug-less approach without heat loss on mechanical plugs including compulsory plasma ignition systems. Then, burned high temperature gas is encased by nearly complete air insulation, because the compressive flow shrinking in focusing process gets over expansion flow generated by combustion. If the compression level based on the supermulti-jets with pistons and cascades added is optimized for a certain size of the present autoignition region between that of very narrow spark ignition and homogeneous-charge compression ignition (HCCI) at very lean burning
The electrification of the powertrain is a prerequisite to meet future fuel consumption limits, while the internal combustion engine (ICE) will remain a key element of most production volume relevant powertrain concepts. High volume applications will be covered by electrified powertrains. The range will include parallel hybrids, 48V- or High voltage Mild- or Full hybrids, up to Serial hybrids. In the first configurations the ICE is the main propulsion, requiring the whole engine speed and load range including the transient operation. At serial hybrid applications the vehicle is generally electrically driven, the ICE provides power to drive the generator, either exclusively or supporting a battery charging concept. As the ICE is not mechanically coupled to the drive train, a reduction of the operating range and thus a partial simplification of the ICE is achievable. The paper shows the advances on a modular powertrain technology approach with different combinations of ICE
This document covers oil transport mechanisms from the power cylinder system which might affect oil consumption. It will not discuss in detail the oil consumption mechanisms from other systems or engine components.
This document covers the mechanisms from the power cylinder which contribute to the mechanical friction of an internal combustion engine. It will not discuss in detail the influence of other engine components or engine driven accessories on friction.
Using a holistic 1D engine simulation approach for the modelling of full-transient engine operation, allows analyzing future engine concepts, including its exhaust gas aftertreatment technology, early in the development process. Thus, this approach enables the investigation of both important fields - the thermodynamic engine process and the aftertreatment system, together with their interaction in a single simulation environment. Regarding the aftertreatment system, the kinetic reaction behavior of state-of-the-art and advanced components, such as Diesel Oxidation Catalysts (DOC) or Selective Catalytic Reduction Soot Filters (SCRF), is being modelled. Furthermore, the authors present the use of the 1D engine and exhaust gas aftertreatment model on use cases of variable valve train (VVT) applications on passenger car (PC) diesel engines. The VVT applications consider a wide range of variables such as exhaust cam phasing, late intake valve opening, Miller, 2nd exhaust event and cylinder
With the increasingly strict emission regulations and economic demands, variable valve trains are gaining in importance in Diesel engines. A valve control strategy has a great impact on the in-cylinder charge motions, turbulence level, thus also on the combustion and emission formation. In order to predict in-cylinder charge motions and turbulence properties for a working process calculation, a zero−/quasi-dimensional flow model is developed for the Diesel engines with a fully variable valve train. For the purpose of better understanding the in-cylinder flow phenomena, detailed 3D CFD simulations of intake and compression strokes are performed at different operating conditions with various piston configurations. In the course of model development, global in-cylinder charge motions are assigned to idealized flow fields. Among them, swirl flow is characterized by an engine swirl number that is determined by both developments of the swirl angular momentum and the moment of inertia. The
The internal combustion engine is still the most important propulsion system for individual mobility. Especially for the application of motorcycles and recreation vehicles the extraordinary high power density is crucial. Today, these engines are mainly 4-stroke naturally aspirated MPFI engines. The main difference to the automotive sector is the abandonment of all cost intensive technologies, like variable valve timing, intake air charging or gasoline direct injection. The need for further investigations and implementation of new technologies is given due to the very high share of total road transport emissions of motorcycles and the introduction of the emission limits of EURO5 in 2020. One possibility to reach the future emission limits is the downsizing strategy. For this, the potential for emission and fuel consumption reduction is well known. The question remains if this technology is applicable for high revolution engines without any variability in the valve train, an
The CO2 reduction required by legislation represents a major challenge to the OEMs now and in the future. The use of fuel consumption saving potentials of friction-causing engine components can make a significant contribution. Boundary potential aspects of a combustion engine offer a good opportunity for estimating fuel consumption potentials. As a result, the focus of development is placed on components with great saving potentials. Friction investigations using the motored method are still state of the art. The disadvantages using this kind of friction measurement method are incorrect engine operating conditions like cylinder pressure, piston and liner temperatures, piston secondary movement and warm deformations which can lead to incorrect measurement results compared to a fired engine. In the past, two friction measurement methods came up, the so called floating liner method and a motored friction measurement with external charging. Both methods are getting closer to realistic
Current heavy duty diesel valvetrains are not able to utilize hydraulic lash adjusters (HLA) in conjunction with an engine brake. During a braking event the engine brake introduces substantial lash into the vehicle valvetrain. The HLA reacts by pumping out to take up the lash encountered during braking, thereby preventing the valves from properly seating at the end of the cycle. Jacobs Vehicle Systems has developed a new mechanism to allow the inclusion of an engine brake into a valvetrain equipped with hydraulic lash adjusters. The fulcrum system maintains a load on the hydraulic lash adjuster during engine brake operation preventing the HLA from extending. HLA are appealing to engine manufacturers because they allow for simpler manufacturing, less maintenance, reduced NVH and valve motion enhancements. This paper describes the design, simulation and testing of the lashless valvetrain with engine brake including the next steps in the development of the valvetrain.
The second generation 1.8L Gasoline Direct Injection Compression Ignition (GDCI) engine was built and tested using RON91 gasoline. The engine is intended to meet stringent US Tier 3 emissions standards with diesel-like fuel efficiency. The engine utilizes a fulltime, partially premixed combustion process without combustion mode switching. The second generation engine features a pentroof combustion chamber, 400 bar central-mounted injector, 15:1 compression ratio, and low swirl and squish. Improvements were made to all engine subsystems including fuel injection, valve train, thermal management, piston and ring pack, lubrication, EGR, boost, and aftertreatment. Low firing friction was a major engine design objective. Preliminary test results indicated good improvement in brake specific fuel consumption (BSFC) over the first generation GDCI engines, while meeting targets for engine out emissions, combustion noise and stability. BSFC at the 2000 RPM-2 bar BMEP global test point was 248 g
Lean burn operation allows small cogeneration engines to achieve both high efficiency and low NOx emissions. While further mixture dilution enables future emission standards to be met, it leads to retarded combustion phasing and losses in indicated engine efficiency. In the case of naturally aspirated engines, IMEP drops due to lower fuel fraction, increasing brake specific fuel consumption. In this work, an alternative engine configuration was investigated that improves the trade-off between engine efficiency, NOx emissions and IMEP. It combines well-established means such as Miller/Atkinson valve timing and optimised intake system for a single-cylinder cogeneration engine, operating with homogenous lean air-natural gas mixture. First, the engine configuration was analysed using a detailed 1D CFD model, implying a significant potential in reaching the project target. In order to prove the positive effect also experimentally, comparable Miller/Atkinson valve timings (i.e. same
The continuously decreasing emission limits lead to a growing importance of exhaust aftertreatment in Diesel engines. Hence, methods for achieving a rapid catalyst light-off after engine cold start and for maintaining the catalyst temperature during low load operation will become more and more necessary. The present work evaluates several valve timing strategies concerning their ability for doing so. For this purpose, simulations as well as experimental investigations were conducted. A special focus of simulation was on pointing out the relevance of exhaust temperature, mass flow and enthalpy for these thermomanagement tasks. An increase of exhaust temperature is beneficial for both catalyst heat-up and maintaining catalyst temperature. In case of the exhaust mass flow, high values are advantageous only in case of a catalyst heat-up process, while maintaining catalyst temperature is supported by a low mass flow. Another focus of simulation was on analyzing the exhaust temperature
This paper proposes a novel engine starter system composed of a small-power electric motor and a simple mechanical valve train. The system makes it possible to design more efficient starters than conventional systems, and it is especially effective to restart engines equipped with idling stop systems. Recently, several idling stop systems, having intelligent start-up functions and highly-efficient generate capabilities have been proposed for motorcycles. One of challenges of the idling stop systems is the downsizing of electric motors for starting-up. However, there are many limitations to downsize the electric motors in the conventional idling stop systems, since the systems utilize the forward-rotational torque of the electric motors to compress the air-fuel mixture gas in the cylinders. Our studies exceeded the limitations of downsizing the electric motors by mainly using the engine combustion energy instead of the electric energy to go over the first compression top dead center
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