Browse Topic: Valves

Items (648)
The purpose of this aerospace information report is to provide a listing of national and international metric standards for use in aerospace fluid systems with their equivalent SAE inch, International ISO, and European AECMA standards.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
This SAE Recommended Practice sets forth a method for evaluating the flow properties of automotive sealers that have been dispensed via a high pressure automatic system.
Materials, Processes and Parts Council
The “system emissions chart” contained herein is intended to serve as a means of estimating the annual refrigerant emission rate (grams per year) from new production A/C systems equipped with specified component technologies. It provides emission values for various component technologies that are currently available, and can be expanded as new technologies are commercialized. This document provides the information to develop an Excel file template “system emissions chart” for system emission analysis. The chart includes automotive compressor technologies for conventional mobile air conditioning systems, as well as those using semi-hermetic compressors. This standard can be considered a companion document to SAE J2763. SAE J2727 estimates system emissions, taking into account production assembly variation and accounts for components that are 100% helium leak tested prior to vehicle final assembly. The results from SAE J2064 are used to better represent permeation emissions from different hose material and coupling configurations in this version. SAE J2763 may be used to quantify emissions from properly assembled systems.
Interior Climate Control Vehicle OEM Committee
Development of Impact Force 1D Model for Powertrain Component2019-01-15496/5/2019
Electromagnetic valves excellent in sealing properties and resistant to sliding are often used in powertrain equipment installed in gasoline- or diesel-engine vehicles. An electromagnetic valve has the function of moving internal valve members by means of electromagnetic force generated by the application of a voltage and thereby changing the flow path. When an electromagnetic valve operates, however, the valve members impact with one another, emitting impact noise caused by it. With the requirement for low noise in electromagnetic valves having become stricter recently from the viewpoint of comfort in the passenger compartment, predicting the noise is needed at the design stage. With this background, this paper describes the development of a 1D model of impact force that will enable the noise and the product performance to be examined simultaneously for a GDI (gasoline direct injection) high pressure pump. In contrast to the conventional model in which a movable member is taken as a mass point with a spring and a damper placed at the impact section, this paper proposes a technique in which a spring-mass model with plural mass points is defined a basis on an eigenvalue of the movable member, verifying both models using measurement. In comparison with the conventional model, the proposed model can more exactly calculate the eigenvalues each of the three impact states in the opening operation of an electromagnetic valve. This allows one to improve that the accuracy in calculating the time characteristics of the force. This paper, in addition, gives cases of use of the developed model in studying the reduction of the force. Reducing the stiffness of the member exposed to impact force enabled the reduction in the high-frequency components of the force to be calculated with high precision, and the accompanying reduction in impact noise was confirmed on the actual machine.
Yoshimaru, YumaKondo, MakotoOmuro, YukieInaba, Masashi
Applies to hydraulic fluid power valves as applied to Off-Road Self-Propelled Work Machines defined in SAE J1116.
CTTC C1, Hydraulic Systems
R410A Based Automotive Heat Pump System That Hits Cabin Heating Goal Successfully in -30 °C Extreme Ambient2019-01-09104/2/2019
To meet low ambient challenges on Battery based Electric Vehicles (BEV), it is necessary to employ heat pump systems on the HVAC systems. However, due to the boiling points limitation of the regular refrigerant R134A/R1234YF, even with Vapor Injection cycle (VI) added, due to -26°C Boiling Temperature (BT) limitation, it is still encountering serious challenges to meet -30 °C or lower ambient needs, although VI Heat Pump (VI H/P) may reach COP>=1.7 at ambient -18 °C. An alternative low BT refrigerant, R410A, plus VI participation, the combination provides potentials to operate in extreme low ambient like -30 °C. In order to find out the actual heating performance of R410A+VI, a demonstration fleet of three vehicles had been built up for road tests to compare each other, which consists of a traditional vehicle (ICE gas heating), a BEV with PTC water heating system (R134A) and a BEV with VI heat pump system (R410A). The testing area covers the coldest city in China such as Harbin, (-20°C), Yakeshi (-39 °C), The road tests have exhibited positive results that the R410A based VI H/P cabin heating system fulfills requirements essentially both for passengers comfort and defrosting/demising. This paper is to summarize the information of the experiments related, including vehicle information, H/P thermal loop, the components applied etc. Meanwhile, it opens some environmental concerns of R410A application on vehicular HVAC systems.
Zhai, KelvinChen, Xuefeng
Visual Analyses of End of Injection Liquid Structures and the Behaviour of Nozzle Surface-Bound Fuel in a Direct Injection Diesel Engine2019-01-00591/15/2019
For efficiency, the majority of modern diesel engines implement multiple injection strategies, increasing the frequency of transient injection phases and thus, end of injection (EOI) events. Recent advances in diagnostic techniques have identified several EOI phenomena pertinent to nozzle surface wetting as a precursor for deposit formation and a potential contributor towards pollutant emissions. To investigate the underlying processes, highspeed optical measurements at the microscopic scale were performed inside a motored diesel engine under low load/idling conditions. Visualisation of the injector nozzle surface and near nozzle region permitted an indepth analysis of the post-injection phenomena and the behaviour of fuel films on the nozzle surface when the engine is not fired. Inspection of the high-speed video data enabled an interpretation of the fluid dynamics leading to surface wetting, elucidating the mechanisms of deposition and spreading. As the needle re-seated, the abrupt pressure drop inhibited atomisation. Large, slow moving, liquid structures were released into the cylinder with the capability of impinging on nearby surfaces, creating localised fuel rich regions, or escaping through the exhaust and contributing towards un-burnt hydrocarbon emissions. Large ligaments remained attached to the nozzle, with some fluid subsequently breaking away while the remaining fuel adhering the nozzle retracted back causing surface wetting. The EOI event was succeeded by further surface wetting due to the expansion of orifice-trapped gas dislodging nozzle-residing fuel that then overspilled onto the external surface. The drop in in-cylinder pressure elicited bubbling within the surface-bound fuel, further increasing the films spreading rate. The resulting bubble agglomerations collapsed in large chain reactions, projecting more fuel into the cylinder. Finally, as the intake valves closed, high velocity intake air was diverted towards the nozzle removing the remaining surface-bound fuel. As a result, a large volume of fuel was released into the combustion chamber after the EOI causing deposits on nearby surfaces or getting released through the exhaust where it would contribute towards un-burnt hydrocarbon emissions. It is likely that the anticipated increase in in-cylinder pressure and temperature if the engine was fired would either reduce the time-scale of these event or completely inhibit them. However, understanding the behaviour of the surface-bound fuel within this environment will aid designs that control surface wetting, thus inhibiting nozzle coking with the capacity to control internal deposits.
Sykes, Dande Sercey, GuillaumeGold, MartinPearson, RichardCrua, Cyril
Dynamic Exhaust Valve Flow 1-D Modelling During Blowdown Conditions2019-01-00581/15/2019
To conduct system level studies on internal combustion engines reduced order models are required in order to keep the computational load below reasonable limits. By its nature a reduced order model is a simplification of reality and may introduce modeling errors. However what is of interest is the size of the error and if it is possible to reduce the error by some method. A popular system level study is gas exchange and in this paper the focus is on the exhaust valve. Generally the valve is modeled as an ideal nozzle where the flow losses are captured by reducing the flow area. As the valve moves slowly compared to the flow the process is assumed to be quasi-steady, i.e. interpolation between steady-flow measurements can be used to describe the dynamic process during valve opening. These measurements are generally done at low pressure drops, as the influence of pressure ratio is assumed to be negligible. As it is very difficult to measure time-resolved mass flow it is hard to test validity of these modeling assumptions. Experimental data indicates that the model overestimates valve flow during the blowdown event. As the blowdown pulse contains a significant portion of the energy in the cylinder at exhaust valve opening, it is therefore of importance to model this correctly. In this paper experimental results from previously published research have been compared to simulation results and the deviation from quasi-steady behavior has been quantified. The deviation appears to be a function of pressure ratio over the valve and valve opening speed. A model is proposed to compensate for the observed effects.
Holmberg, TedCronhjort, AndreasStenlaas, Ola
Valve Flow Coefficients under Engine Operation Conditions: Pressure Ratios, Pressure and Temperature Levels2019-01-00411/15/2019
Engine valve flow coefficients are not only used to characterize the performance of valve/port designs, but also for modelling gas exchange in 0D/1D engine simulation. Flow coefficients are usually estimated with small pressure ratios and at ambient air conditions. In contrast, the ranges for pressure ratio, pressure and temperature level during engine operation are much more extensive. In this work the influences of these three parameters on SI engine poppet valve flow coefficients are investigated using 3D CFD and measurements for validation. While former investigations already showed some pressure ratio dependencies by measurement, here the use of 3D CFD allows a more comprehensive analysis and a deeper understanding of the relevant effects. At first, typical ranges for the three mentioned parameters during engine operation are presented. A preliminary study for a simple nozzle geometry shows the suitability of the utilized 3D CFD code for partially overcritical flow, and demonstrates the limits of the fundamental nozzle flow equation. Steady flow simulations of two different four-stroke SI engine cylinder head geometries reveal that valve flow coefficients show noticeable dependencies on all three named parameters especially for small valve lifts, and flow direction from port into cylinder. Pressure recovery within and downstream valve gap influenced by valve gap boundary layer height is identified to be responsible for this behavior. In the reverse flow direction the existence of pressure recovery can also be confirmed, but its effects are found to be superimposed by flow necking and separation effects which especially depend on valve design. For validation, the 3D CFD results are compared with valve flow coefficients measured at flow test bench with extended pressure ratios and pressure levels. The measurements confirm the valve flow coefficient dependencies found by simulations.
Fasse, SvenGrill, MichaelBargende, Michael
Development of a Climate and Altitude Simulation Test Bench for Handheld Power Tools2018-32-003310/30/2018
A climate and altitude conditioning test bench was developed at the Institute of Energy Efficient Mobility (IEEM) of Karlsruhe University of Applied Sciences to evaluate the overall sustainability of using innovative biofuels in handheld power tools such as chainsaws, trimmers and blowers under any typical operating condition worldwide. The 6 m3 hermetically sealed and thermally insulated test chamber is large enough to fit the entire power tool. A two-stage refrigeration system with intake air drying and electric heating allows for realistic temperature conditions to be set in the test chamber, ranging from arctic cold to tropical heat (-28 to 45 °C). Altitudes of up to 3500 m above sea level can be simulated using a throttle valve at the inlet of the chamber and a pressure-controlled rotary screw compressor positioned downstream the test chamber outlet. The air-cooled engines to be tested are fully exposed to the ambient conditions inside the test chamber, are able to aspirate the conditioned combustion air freely and release both exhaust gas and waste heat into the chamber environment. In order to control the power tool’s operation when the chamber is closed, an adaptive remote control system was specially developed. It enables automatic engine start-up by cable pull (e.g. for cold start testing), engaging the choke valve as well as operating the throttle lever automatically. This paper discusses the development process, the design, the operating limits of the climate and altitude simulation test bench as well as first tests on the reproducibility of the automatic start procedure, particularly important for future cold start investigations.
Martel, ArturScholl, FinoWeierter, DennisKettner, Maurice
Mixture Formation and Combustion Evaluation of a Motorcycle Engine Concept Equipped with One Fuel Injector for Each Intake Valve2018-32-000910/30/2018
In light of a more stringent emission legislation and in anticipation of possible future measures to further reduce the real environmental impact of motorcycles, it is necessary to develop engine concepts which are efficient and low on emissions in a wide range of operating points. This poses an important challenge on the development of high performance motorcycles engines as their focus on full load behaviour conflicts sharply with the emission and efficiency demands of the remaining engine load map. The focus of this paper is to evaluate the potential of a port fuel injection (PFI) concept consisting of one individual fuel injector for each intake valve to solve this trade-off. Previous research shows a positive effect of such a setup on mixture formation due to better targeting and atomization, reducing HC emissions and cyclic variations. It also shows improved efficiency, performance and knocking characteristics caused by an enhanced charge cooling effect through open valve injection (OVI). Although the system has been previously investigated, the necessary layout considerations and impacts of the system for a high performance motorcycle engine have not yet been addressed. In this work the mentioned PFI concept was studied using a high performance two-cylinder motorcycle engine. Engine tests were conducted for two injector sets having different static flow values. The results showed improved efficiency and lower HC emissions for higher engine loads, but no performance gain at full load. The reasons for this behaviour were closely analysed by means of CFD simulation and thermodynamic loss analysis of the combustion process. These explanations were further confirmed by additional engine tests using exhaust gas sampling with fast FID. As a final result a set of recommendations for further concept improvement is proposed.
Gaitan, PedroSchwarz, FrankEibl, Rüdiger
CFD Analysis of a Port Fuel Injection IC Engine to Study Air-Fuel Mixture Preparation and Its Impact on Hydrocarbon Emission and Mixture Homogeneity in Combustion Chamber2018-32-000510/30/2018
At part load conditions, effective utilization of fuel is critical for drivability of an IC engine driven automobile, with minimum emissions and fuel consumption. It becomes cardinal to study the mixture preparation in engines to understand the injection strategy that helps in achieving the prime objectives of lower emission and reliable operation. To add to the complexity of the problem being studied, the injection phenomenon is rapid, turbulent, multi-phase, two-way coupled (where the continuous phase affects the droplets and vice versa) and involves turbulence length scales and time scales, few orders of magnitude lower compared to the characteristic length in the turbulence integral scale. A methodology is developed in Star-CD and ES-ICE to simulate the mixture preparation in Port Fuel Injection (PFI) engines. High quality mixture preparation which is essential for combustion stability and lower emissions is aimed at part load conditions which constitute the majority of driving cycle. This methodology is helpful to understand and solve the injection timing development issues and in improving the combustion stability and lowering the emissions. The fuel injection parameters have been studied in detail both experimentally and numerically in a specialized spray chamber. The fuel injection parameters are correlated to the source of injection to obtain similar fit of droplet distribution profile obtained experimentally. The parameters like - injection timing, injection location and injection pressure can be efficiently optimized through this methodology for efficient mixture formation. Extensive studies have been done on different injection timing in order to reduce the wall film thickness and fuel short circuit losses and to increase the overall evaporation rate of fuel droplets by increasing the residence time. Two injection timing strategies namely - open valve injection and closed valve injection have been analyzed to understand the effect of fuel short circuit losses and its impact on HC (hydro-carbon) emissions. It is observed that, open valve injection has lower short circuit losses compared to closed valve injection, which is experimentally verified and thus has a great significance in reducing the HC emissions. However, open valve injection comparatively affects the in-cylinder charge homogeneity and standard deviation of equivalence ratio. This paper also discusses on the strategies that have been undertaken to achieve best-in-cylinder homogeneity with an adverse effect on increased fuel film thickness on the port walls. Efforts are made to optimize the injection timing and location for best mixture formation in production automotive vehicles and in extending the methodology for the corresponding emission prediction. Being a computationally intensive problem with an additional complexity of moving mesh, opens an opportunity for parallel performance study. Parallel performance study shows that the methodology proposed above uses a Message Passing Interface (MPI) and shows a good scale up for 2-16 cores, above which it saturates. Multi-cycle analysis is carried out to understand the variation in Air-Fuel ratio homogeneity and Coefficient of variation of Indicated Mean Effective Pressure (IMEP) which provides a fundamental vista on the transient behavior of the spray dynamics.
G B, ArivazhaganGarg, Manish
Open-Loop Characteristics Analysis and Control of High Speed On-Off Valve2018-01-186810/5/2018
In the process of ABS control, the Anti-lock braking system (ABS) of the vehicle adjusts the wheel cylinder brake pressure through the hydraulic actuator so as to control the movement of the wheel. The high-speed on-off valve (HSV) is the key components of the Anti-lock braking system. HSV affects the performance of the hydraulic actuator and the valve response characteristics affects the Anti-lock braking system pressure response as well as braking effect. In this paper, the electromagnetic field theory and flow field theory of HSV are analyzed, and simulation analysis of electromagnetic field characteristics of HSV is done by ANSYS. Combined with the ANSYS analysis results, a precise physical model of HSV is constructed in AMESim. Meanwhile, the valve response characteristics are analyzed. Moreover, the influence of different wheel cylinder diameter and PWM carrier frequency on hydraulic braking force characteristics are analyzed. The open-loop control methods of hydraulic braking force based on Look-up tables and T-S fuzzy structure are comparatively analyzed. The results show that T-S fuzzy controller can be more direct and rapid training to obtain buck-boost surface without fitting and interpolation of data surface, it is more adaptable. The single-wheel model and ABS sliding mode control module are established in Simulink. The inner ring of the module is hydraulic brake force controller, it is used to control hydraulic braking force precisely. The outer ring of the module is a sliding mode controller to control the wheel slip rate. Based on the above two open-loop control strategies, ABS control can be better achieved to realize anti-lock control of the vehicle in the emergency braking conditions.
Zhuo, GuirongShen, HuadongXue, RuonanWu, Shenchen
Study of Swirl Ratio on Mixture Preparation with a Swirl Control Valve in a Diesel Engine2018-01-17909/10/2018
Downsizing as a main-stream technology was widely used for design of future diesel engines in order to meet the increasingly stringent demands of emissions regulation and reduction of CO2 production. Design of intake system faces a considerable challenge accordingly. Discharge coefficient and swirl ratio as two main factors of intake port design have been widely investigated by researchers. However, these two parameters indicate a trade-off relationship. Therefore, it is difficult for a classical intake system to achieve a good balance between sufficient air charge and decent air-fuel radial mixing quality. A 1 L twin-intake-port single-cylinder diesel engine was studied in this paper. A swirl control valve designed to adjust the effective flow area of the filling port, was installed between the intake manifold and the intake filling port in order to achieve variation of swirl ratio. And there is no control valve for the intake spiral port. Influence of varied angles of the swirl control valve on the discharge coefficient and the swirl ratio of intake ports were firstly investigated on a steady flow rig. Then Particle Image Velocimetry (PIV) technique was used to visualize the in-cylinder swirl motion. Besides, CFD method was used to evaluate the effects of varied valve angles on the following air-fuel mixing process in the cylinder. The results show that CFD reveals the in-cylinder flow structure and the location of swirl center similar with the 3D-PIV test results. With the increase of swirl ratio at IVC from 0.57 to 2.05, air-spray interaction in the circumferential direction is strengthened in the terms of mixture preparation. Strong swirl motion accelerates the heat release during the premixed combustion stage, which results in an advancement of CA50 and a reduction of combustion duration. High swirl motion intensity makes a positive effect on the increase of accumulated heat release under the same air flow mass rate.
Li, HaiyingWang, LeiWang, KunZhu, WeiqingLi, YufengJiang, Li
Development of a New 1.8L Down-Speeding Turbocharged Gasoline Engine with Miller Cycle2018-01-17129/10/2018
Upcoming China 4th stage of fuel consumption regulation and China 6a emission legislation require improvement of many existing engines. This paper summarizes an upgrade of combustion system and mechanical layout for a four-cylinder engine family. Based on an existing production process for a naturally aspirated 2.0-liter gasoline engine, a 1.8-liter down-speeded and turbocharged gasoline engine is derived. Starting development by analysis of engine base geometry, a layout for a Miller-Cycle gas exchange with early closing of intake valves is chosen. Requirements on turbocharger configuration are investigated with one-dimensional gas exchange simulation and combustion process will be analyzed by means of 3D-CFD simulation. Challenging boundary conditions of a very moderate long-stroke layout with a stroke/bore-ratio of only 1.037 in combination with a cost efficient port fuel injection system and fixed valve lift profiles are considered. To compensate reduced in-cylinder charge motion of small valve lift three measures are taken. Firstly, the intake port is modified for significantly increased tumble motion at higher valve lift. This is combined with a masking of the intake valve area in the combustion chamber and enables a high turbulence even at very small valve lift. Finally, the valve lift profile is optimized by changing cylinder head layout from tappet valve train to roller-finger follower. This has also positive impact on friction behavior. Further reduction of parasitic losses by reduced main bearing diameter, adapted piston ring layout and introduction of an oil pump with two pressure stages accompanies the increase of combustion efficiency. The development targets with almost ninety-two percent of the maximum torque achieved at an engine speed 1250 rpm and a minimum specific fuel consumption of 230 g/kWh are reached, which means maximum thermal efficiency of 36.8% normalizing to caloric value of 42.5 MJ/kg.
Ye, YisuXu, LibingWang, JinshiYao, KefuZhao, MingxiangDieterich, CarstenSouren, MikeMorcinkowski, Bastian
Effects of Valve Deactivation on Thermal Efficiency in a Direct Injection Spark Ignition Engine under Dilute Conditions2018-01-08924/3/2018
Reported in the current paper is a study into the cycle efficiency effects of utilising a complex valvetrain mechanism in order to generate variable in-cylinder charge motion and therefore alter the dilution tolerance of a Direct Injection Spark Ignition (DISI) engine. A Jaguar Land Rover Single Cylinder Research Engine (SCRE) was operated at a number of engine speeds and loads with the dilution fraction varied accordingly (excess air (lean), external Exhaust Gas Residuals (EGR) or some combination of both). For each engine speed, load and dilution fraction, the engine was operated with either both intake valves fully open - Dual Valve Actuation (DVA) - or one valve completely closed - Single Valve Actuation (SVA) mode. The engine was operated in DVA and SVA modes with EGR fractions up to 20% with the excess air dilution (Lambda) increased (to approximately 1.8) until combustion stability was duly compromised. At 1500 Revolutions Per Minute (RPM), 3.6 bar and 7.9 bar Gross Mean effective Pressure (GMEP), the dilution tolerance of the engine was significantly increased for a given combustion stability limit utilising SVA. This resulted in fuel consumption reductions of up to 3.8% and 3.1% respectively for these two engine speed and load conditions as a result of being able to operate the engine with more thermodynamically attractive mixtures when adopting SVA. At 2000RPM, 9.8 bar GMEP, the dilution tolerance was only marginally increased which resulted in a fuel consumption reduction of 1.3% when adopting SVA over DVA (for the same reasons outlined above). Increased dilution tolerance in all cases was achieved as a result of significant enhancement in charge motion when adopting SVA. By enhancing the in-cylinder charge motion (confirmed using Computational Fluid Dynamics (CFD)), ignition to 10% Mass Fraction Burned (MFB) and 10-90% MFB durations for equivalent levels of dilution were significantly shorter when adopting SVA. This therefore allowed greater dilution tolerance (and ultimately an increase in the thermal efficiency of the working cycle) when adopting SVA over DVA without detrimental increases in the burn duration metrics that would ordinarily result in misfire and partial burn and a significant detriment to combustion stability. Conversely, for equivalent levels of dilution, there was little, if any difference in fuel consumption between DVA and SVA even though burn duration metrics were significantly shorter when adopting SVA over DVA. In combination with CFD, the polytropic coefficient of compression was calculated to be lower in all cases for SVA compared to DVA for a given level of dilution. This indicated greater heat transfer when adopting SVA over DVA for equivalent trapped mass (confirmed using CFD). As such, this detrimental increased heat transfer (again confirmed with CFD) attributed to the increased in-cylinder activity with SVA offset the favourably faster combustion; thus resulting in little, if any reduction in fuel consumption for equivalent levels of dilution when implementing SVA over DVA. This was particularly pertinent at the higher engine speed and load where the significantly increased heat transfer for SVA resulted in an increase in fuel consumption for SVA over DVA for equivalent levels of dilution.
Roberts, Philip JohnKountouriotis, AlexandrosOkroj, PawelAleiferis, PavlosCooper, Brian
Study on the Delay Characteristics of Electric Unit Pump2018-01-03134/3/2018
Accurate injection timing is necessary for the coordination of fuel injection system, intake system and combustion chamber. However, the electric unit pump has obvious delay characteristic, so the delay characteristics of electric unit pump were studied in this paper. Five main parameters of the delay characteristics were defined, which were namely electronic delay, electromagnetic delay, electro hydraulic delay, hydraulic delay and mechanical delay. Then six delay points were determined such as current generation delay, solenoid valve closing delay, injector opening delay, injection delay, solenoid valve opening delay and fuel pressure relief delay by analyzing the working process of the system. Based on the method of experiment, the change rules of the delay time were obtained at different input conditions by changing the parameters of cam speed, injection pulse width, injection timing, peak current and holding current finally. The result shows that the injector opening delay time decreases, the fuel pressure relief delay time increases and the other delay times remain steady as the cam speed increases. The fuel pressure relief delay time increases and then decreases, the other delay times remain steady in the range of injection pulse width 8~15°CAM. The injector opening delay time decreases and then increases, the fuel pressure relief delay time increases and the other delay times remain steady in the range of injection timing −8~8°CAM. The solenoid valve closing delay time decreases, the injector opening delay time and the fuel pressure relief delay time increases, and the other delay times remain steady as peak current increases. The solenoid valve opening delay time increases and the other delay times remain steady as holding current increases. The results provide a reference for precise control of injection timing.
Xu, YangLiu, Fushui
Experimental Analysis of Fuel and Injector Body Temperature Effect on the Hydraulic Behavior of Latest Generation Common Rail Injection Systems2018-01-02824/3/2018
The present paper describes the effect of thermal conditions on the hydraulic behavior of Diesel common rail injectors, with a particular focus on low temperatures for fuel and injector body. The actual injection system thermal state can significantly influence both the injected quantity and the injection shape, requiring proper amendments to the base engine calibration in order to preserve the combustion efficiency and pollutant emissions levels. In particular, the introduction of the RDE (Real Driving Emission) test cycle widens the effective ambient temperature range for the homologation cycle, this way stressing the importance of the thermal effects analysis. An experimental test bench was developed in order to characterize the injector in an engine-like configuration, i.e. fuel pump, piping, common rail, pressure control system and injectors. One of the injectors is used for the measurement of injection rate time profile by means of a Zeuch method-based injection analyzer, mean injected volume per shot and dynamic pressure time-history at pump outlet and injector inlet. The fuel temperature, measured at the fuel pump inlet, and the injector body temperature are independently conditioned in a range between −10 °C and 90 °C. Latest generation common rail injectors - featuring the first a pressure-balanced pilot stage, the other a three-way valve pilot stage respectively - were tested over a wide range of thermal conditions as combination of fuel and injector body temperatures, injection pressure level (up to 2000 bar), and injection strategies (solo-main, pilot-main and main-post injection patterns). The experimental results showed a strong effect of thermal conditions on the injector hydraulics. The injected volume can be varied up to 30% compared to the reference operating condition (Tfuel = 40 °C, Tbody = 90 °C). The injection rate analysis evidenced that the injector closure timing can be seriously affected by the system thermal state, while the nozzle steady flow is typically less influenced by the fuel and injector body temperature in the examined range. It was also evidenced a different temperature effect for different pilot stage architectures. In one case the temperature reduction led to an injection volume decrease and in the other case, comparable differences where observed but with a completely opposite trend.
Cavicchi, AndreaPostrioti, LucioPesce, Francesco ConcettoFerrara, Umberto
Sodium Cooling Efficiency in Hollow Valves for Heavy Duty Engines2018-01-03684/3/2018
As a consequence of the ongoing evolution of engines, where performance is continuously improving and the use of alternative fuels is being adopted by many engine manufacturers, thermal working conditions of the exhaust valves are increasingly critical. In order to better resist the higher temperature levels of the exhaust gases, current development ranges from improvement of the cooling concept for the overall system, new materials for valve set components up to the upgrade of the exhaust manifold material. Change in the design of several valvetrain components due to the increased thermal loads is a logical consequence of this technical evolution process. Hollow exhaust valves filled with Sodium (Na) are a known technology that is widely used in passenger car engines to improve thermal behavior and to avoid the need to change to expensive materials (Ni-base alloys). Nevertheless, shaker-cooling effect of Na for engine speeds below 3.000 [rpm] has been questioned in the past and this technology has not been fully explored in heavy duty (HD) applications [1]. In order to investigate the thermal efficiency or effectiveness and to confirm Na-filled valves as a potential technical solution for thermal issues in HD engines, back-to-back analyses (FEA) and tests (temperature measurements and endurance) were performed, mainly focused on heavy duty spark ignition (SI) engines (gas fueled) and on severe applications of diesel engines.
Zenklusen, FernandoCoenca, MarcioPuck, Alexander
Refinement of a 0D Turbulence Model to Predict Tumble and Turbulent Intensity in SI Engines. Part I: 3D Analyses2018-01-08504/3/2018
Recently, a growing interest in the development of more accurate phenomenological turbulence models is observed, since this is a key pre-requisite to properly describe the burn rate in quasi-dimensional combustion models. The latter are increasingly utilized to predict engine performance in very different operating conditions, also including unconventional valve control strategies, such as EIVC or LIVC. Therefore, a reliable phenomenological turbulence model should be able to physically relate the actuated valve strategy to turbulence level during the engine cycle, with particular care in the angular phase when the combustion takes place. Similarly, the capability to sense the effects of engine architecture and intake geometry would improve the turbulence model reliability. 3D-CFD codes are recognized to be able to accurately forecast the evolution of the in-cylinder turbulence field, taking into account both geometrical features (compression ratio, bore-to-stroke ratio, intake runner orientation, valve, piston and head shapes, etc.) and operating conditions (engine speed, boost level, valve strategy). Instead, more common 0D turbulence models usually synthesize geometrical effects in a number of tuning constants and “try” to be sensitive to the operating conditions as much as possible. In this two-part paper, the final goal is the refinement of a previously developed 0D turbulence model, here extended to directly predict the tumble vortex intensity and its close-to-TDC collapse into turbulence. In addition, the model is enhanced to become sensitive to engine geometrical characteristics, such as intake runner orientation, compression ratio, bore-to-stroke ratio and valve number, without requiring any preliminary estimation of the tumble coefficient on a flow bench. Part I describes a background study, where 3D analyses are performed to highlight the effects of operating conditions and main engine geometrical parameters on tumble and turbulence evolution during the engine cycle. In a preliminary stage, the averaging process influence to define representative quantities of mean flow and turbulence is discussed, in order to take into account not-uniformities inside the combustion chamber. 3D simulations are carried out under motored conditions on a VVA engine, at various engine speeds. The VVA device is controlled to simulate both standard, early and late valve closures. The results highlight substantial differences in the mean flow velocity, turbulence intensity and tumble speed among the above cases. To focus the engine geometry impact on the turbulence evolution, further analyses are performed on a different engine, by changing the angle between the intake runners and the cylinder axis. The geometrical compression ratio and the bore-to-stroke ratio are modified, as well. Finally, a two-valve version of this engine is also considered. Results of 3D analyses are discussed to widely assess the effects of valve strategy and main engine geometrical parameters on mean flow, tumble and turbulence evolution inside the combustion chamber. The presented information constitute an extended database for the development and validation of a refined quasi-dimensional model, discussed in the companion part II of the paper.
Bozza, FabioDe Bellis, VincenzoBerni, FabioD'Adamo, AlessandroMaresca, Luigi
Variable Valve Actuation Strategies for Better Efficiency Load Range and Thermal Management in an RCCI Engine2018-01-02544/3/2018
The Reactivity Controlled Compression Ignition concept for dual-fuel engines has multiple challenges of which some can be overcome using Variable Valve Actuation approaches. For various fuel combinations, the engine research community has shown that running dual-fuel engines in RCCI mode, improves thermal efficiency and results in ultra-low engine-out nitrous oxides and soot. However, stable RCCI combustion is limited to a certain load range, depending on available hardware. At low loads, the combustion efficiency can drop significantly, whereas at high loads, the maximum in-cylinder pressure can easily exceed the engine design limit. In this paper, three VVA measures to increase load range, improve combustion efficiency, and perform thermal management are presented. Simulation results are used to demonstrate the potential of these VVA measures for a heavy-duty engine running on natural gas and diesel. First, TNO’s multi-zonal combustion model is introduced and validated using experimental data from a multi-cylinder heavy-duty engine operated in RCCI mode with variable intake timing. This combustion model is used in conjunction with a commercial zero-dimensional engine simulation tool to examine three different VVA strategies, each with its own advantage: 1 Early intake valve closing for extending high load range 2 Late intake valve opening for improved combustion efficiency at low load 3 Exhaust valve double lift for improved combustion efficiency and thermal management (better after-treatment efficiency). The latter two are especially important for dual-fuel engines using natural gas since they offer an effective means for CH4 slip reduction. It is shown that thanks to these measures, a heavy-duty engine can run with natural gas - diesel RCCI in the full load range and that significant CH4 reduction towards Euro VI limits is possible. The paper is concluded with an outlook on options to achieve these goals successfully on a real engine.
Mikulski, MaciejBalakrishnan, Praveen RamanujamDoosje, ErikBekdemir, Cemil
Unsteady Performance Simulation Analysis of a Waste-Gated Turbocharger Turbine under Different Valve Opening Conditions2017-01-241710/8/2017
An electronic waste-gated turbocharger for automotive application can accurately control the boost pressure and effectively reduce turbo-lag. It can improve the transient responsive performance of engine and the acceleration performance of vehicle, which makes vehicle have a better adaptation to the complex traffic environment. A detailed analysis of aerodynamic working principle of electronic wastegate is the foundation for designing the control strategy of electronic wastegate. Putting turbine with electronic wastegate under unsteady condition that simulates the pulse exhaust gas of engine and studying influences of different valve opening on the performance of turbine has the practical value. This paper sets fixed and periodical unsteady conditions and adopts numerical methods to explore the performance of turbine in twin-entry turbocharger and the flow loss of bypass. Steady simulation structure is given for reference. The influence and change rule of wastegate valve opening on turbine performance are researched comprehensively. The results show that the nearer the valve opening approximates to full close, the greater the influence on the turbine unsteady performance is, and the bigger the flow loss in per degree is. The flow loss in the turbine and the bypass are evaluated to reveal the mechanism of influence on turbine performance of valve opening and flow loss. This paper is helpful to optimize the structure of electronic actuator and design the control strategy.
Fan, HouchuanNi, JiminShi, XiuyongJiang, NanQu, DayongZheng, YiZheng, Yinghong
Analysis on the Influence of Key Parameters of Control Valve on the Performance Characteristics of Electromagnetic Injector2017-01-231010/8/2017
The control valve is the most important implementation part of a high pressure common rail system, and its flow characteristics have a great influence on the performance of an injector. In this paper, based on the structure and the working principle of an electromagnetic injector in a high pressure common rail system, a simulation model of the injector is established by AMESim software. Some key parameters of the control valve, including the volume of the control chamber, the diameter of the orifice Z (feeding orifice), the diameter of the orifice A (discharge orifice) and the hole diameter of the fuel diffusion hole are studied by using this model. The results show that these key structural parameters of the control valve have a great influence on the establishment of the control chamber pressure and the action of the needle valve. Within a certain range, when the control chamber volume is small, the control chamber pressure changes rapidly, the needle moves quickly, the system reacts quickly; increasing the diameter of the orifice Z (feeding orifice) facilitates the closing speed of the needle valve but reduces the opening speed of the needle valve; increasing the diameter of the orifice A (discharge orifice), the valve opening speed accelerates, closing delay time unchanged; increasing the diameter of the fuel diffusion hole, the needle closing time increases, the fueling duration time is prolonged and the fuel injection quantity increases. On the basis of this, the cavitation problem at the sealing seat of the control valve sleeve in the common rail injector is simulated by CFD simulation, and the process of cavitation is deduced. In the existing structure, it is possible to reduce the cavitation phenomenon by increasing the length of the fuel diffusion hole of the control valve.
Jia, XiaoyanSun, BaigangWu, DongweiXu, DanZang, WeiShang, WeiWang, Jie
An Intake Valve Deposit (IVD) Engine Test Development to Investigate Deposit Build-Up Mechanism Using a Real Engine2017-01-229110/8/2017
In emerging markets, Port Fuel Injection (PFI) technology retains a higher market share than Gasoline Direct Injection (GDI) technology. In these markets fuel quality remains a concern even despite an overall improvement in quality. Typical PFI engines are sensitive to fuel quality regardless of brand, engine architecture, or cylinder configuration. One of the well-known impacts of fuel quality on PFI engines is the formation of Intake Valve Deposits (IVD). These deposits steadily accumulate over time and can lead to a deterioration of engine performance. IVD formation mechanisms have been characterized in previous studies. However, no test is available on a state-of-the-art engine to study the impact of fuel components on IVD formation. Therefore, a proprietary engine test was developed to test several chemistries. Sixteen fuel blends were tested. The deposit formation mechanism has been studied and analysed. The results of this study indicate that addition of C6 to C16 olefins did not increase the deposit mass, unless the oxidation stability of the resultant gasoline was impaired. The deposit analyses suggested aromatics (including PAH) with a high boiling point or used at high concentrations tend to remain on the valve surface as a deposit. The engine tests also suggest that a small fraction of the base fuel has a disproportionate impact on deposit weight. A high final boiling point of the fuel does not necessarily make a fuel more prone to IVD formation, but rather it depends on the chemical composition of the high boiling components.
Gail, SandroNomura, TakashiHayashi, HitoshiMiura, YuichiroYoshida, KatsumiNatarajan, Vinod
Orthogonal Optimum Design of High-Speed Solenoid Valve for the Injection System of Unit Pump2017-01-219810/8/2017
The electromagnetic valve driving mechanism is the significant equipment, which plays a vital role in the unit pump injection system; therefore, the performance of the electromagnetic valve directly influences the function of the control system. Based on the operation conditions of the unit pump injection system, a steady electromagnetic valve model was modified to study the influence factors of electromagnetic force and the best combination to get the maximum electromagnetic force. The validation model was verified by experiment. The effects of some crucial parameters upon the electromagnetic force were investigated in the present paper, (including working airspace, magnetic pole’s cross-sectional area, coil position, coil turn, the armature thickness). The results show that the electromagnetic force of the solenoid valve enhanced with the increase of driving current and with the decrease of working airspace. Besides that, the electromagnetic force won’t continuously rise if the driving current goes up to the threshold. Such results seem can be employed to explain the magnetic saturation phenomenon. In addition, the electromagnetic force will correspondingly rise with the increasing of armature thickness, increasing of coil turns, closing the coil’s position towards armature’s centre and equalizing the cross-sectional areas of major and vice poles. Based on the calculation, the greatest electromagnetic force was obtained by means of orthogonal design. The results prove that the method is feasible and accurate to obtain the key parameters of the solenoid valve in order to achieve the greatest electromagnetic force. The research results have a great engineering significance to the promotion of the electromagnetic force.
Li, ZhihongLi, GuoxiuWang, LanLi, HongmengWang, JieGuo, HaizhouHe, Shuangyi
Numerical Investigation of the Intake Flow of a Four-Valve Diesel Engine2017-01-221110/8/2017
The intake process plays an important role in the operation of internal combustion engines. In the present study, a three-dimensional transient simulation of a four-valve diesel engine was performed using Large Eddy Simulation (LES) model based on software CONVERGE. The mean velocity components in three directions through the intake valve curtain, the flow separation around the intake valves, the influences of inlet jet on turbulence flow field and cycle-to-cycle variation were investigated in this work. The result shows that the mean velocity distributes non-uniformly near the valve curtain at high valve lifts. In contrast, the mean velocity distribution is uniform at low valve lifts. It is found that the flow separation occurs at valve stem, valve seat and valve sealing through the outlet of the helical port. In contrast, flow separation is only observed in the valve seat through the outlet of the tangential port. It is noted that the flow separation causes the backflow to occur near the valve, which affects the mass of fresh charge significantly. In order to research the influence of the inlet jet on turbulence flow fields, a parameter was proposed in this work, named Jet-Angle, which indicates the angle between the inlet jet centerline and the valve gap centerline. The results show that the orientation of the inlet jet changes regularly with crank angle and the turbulence flow field is influenced by inlet jet significantly. During the early stage of the intake process, the increase of the inlet jet velocity leads to large velocity gradient and strong turbulence intensity. In the latter stage of the intake stroke, the inlet jet velocity decreases and it results in the decrease of turbulence intensity. The cycle-to-cycle variation is weak during the initial stage of the intake stroke, and the cyclic differences intensify during the latter stage of the intake stroke, which is the result of the interaction of inlet jet and vortices in the cylinder.
Jia, MengqiuLu, ZhenWang, TianyouLi, YufengSun, YanzheWen, MingChe, ZhizhaoSun, Kai
A Comparative Study on Influence of EIVC and LIVC on Fuel Economy of A TGDI Engine Part I: Friction Torques of Intake Cams with Different Profiles and Lifts2017-01-224510/8/2017
In order to better understand how the Atkinson cycle and the Miller cycle influence the fuel consumption at different engine speeds and loads, an investigation was conducted to compare influences of early intake valve closing (EIVC) and late intake valve closing (LIVC) on the fuel consumption of a 1.5L turbo-charged gasoline direct injection (TGDI) engine. The engine was tested with three different intake cams, covering three intake durations: 251 degCA (the base engine), 196 degCA (the Miller engine), and 274 degCA (the Atkinson engine). Compression ratios are 9.5:1 for the base engine and 11.4:1 for the Atkinson and Miller engines, achieved with piston modifications. Results of this investigation will be reported in three papers focusing respectively on characteristics of the engine friction, in-cylinder charge motions for different intake events, and combustion and fuel economy without and with EGR for the naturally aspirated mode and boost mode. The present paper is Part I of this investigation. This study reports the results of detailed analyses as well as experiments on characteristics of the cam dynamics and friction forces for the three different intake cams at engine speeds from 700 to 5700 rpm. It was found that, for the three engines investigated in this study, the maximum motoring friction torque for the Atkinson engine was about 3% greater and the Miller engine was about 3% less than that of the base engine. Differences in the engine friction torques decreased with increasing the engine speed, and became insignificant at 5700rpm.
Ouyang, XianlinTeng, Hozeng, XiaochunLuo, XuweiHu, TingjunHuang, XianlongLuo, JiankunZhou, Yongli
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