Browse Topic: Engine components

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BALL BEARINGS.060002To be published on 01/01/2099
HESS, HENRY
Technical Paper
Development of Cylinder Deactivation Control during Idle for Conventional Engines2024-32-001904/18/2025
This report examines the advancement and utilization of cylinder deactivation technology that enhances fuel efficiency in conventional engines without hardware modifications. It operates by halting fuel supply to some of the cylinders in multi-cylinder engines and increasing the output power of the remaining active cylinders to maintain an idle state. By implementing this technology in the mass-produced 90° V-twin engine, the U502, and deactivating one of its two cylinders, fuel consumption during idling is reduced by over 30%. The focus of this study is on the technology developed to minimize engine speed fluctuations during the transition to cylinder deactivation and reactivation for the engine. By making various modifications to the fuel injection control sequence and optimizing the throttle opening of each cylinder in idle and driving conditions, engine speed fluctuations were minimized. This allows users to reduce fuel consumption while maintaining the engine’s original
YANAGIDA, Shoji
Technical Paper
Fuel Film Measurement in a SI Gasoline Engine Using a Newly Developed MEMS Sensor2024-32-007104/18/2025
The previously developed capacitance sensor for detecting a liquid fuel film was modified to apply to the in-cylinder measurement. On the developed sensor surface, comb-shaped electrodes were circularly aligned. The capacitance between the electrodes varies with the liquid fuel film adhering. The capacitance variation between the electrodes on the sensor surface was converted to the frequency variation of the oscillation circuit. In the previous study, it was revealed that the frequency of the oscillation circuit varies with the variation of the liquid fuel coverage area on the sensor surface. The developed sensor was installed in the combustion chamber of the rapid compression and expansion machine, and the performance of the developed sensor was examined. Iso-octane was used as a test fuel to explore the sensor that had been developed. As a result, the adherence of the liquid fuel directly injected into the cylinder was successfully detected under the quiescent and motoring
Kuboyama, Tatsuya, Moriyoshi, Yasuo, Takayama, Satoshi, Nakabeppu, Osamu
Technical Paper
Detailed Approach for Pre-Chamber Heat Release Analysis for the HSASI Pre-Chamber Spark Plug Using a Pressure Sensor Glow Plug2024-32-006304/18/2025
The hot surface-assisted spark ignition (HSASI) pre-chamber spark plug, which was developed at the Karlsruhe University of Applied Sciences, increases the dilution limit with excess air and the tolerance to residual gas in the pre-chamber compared to a conventional passive pre-chamber spark plug. In this study, the conventional glow plug which is integrated in the pre-chamber of the HSASI pre-chamber spark plug was replaced by a pressure sensor glow plug (PSG) from BERU. This allows for a detailed combustion analysis in the pre-chamber. The signal of the PSG was validated with a piezoelectric cylinder pressure sensor and a method to analyse the pre-chamber heat release was introduced. Experimental investigations were carried out on a single-cylinder gasoline engine. A series of operating points diluted with excess air and a variation in load were conducted. The gas flow rate through the orifices of the pre-chamber was calculated from the pressure difference between the pre-chamber and
Holzberger, Sascha, Kettner, Maurice, Kirchberger, Roland
Technical Paper
Statistical Analysis of Data Acquired from Propagating Flames in Gasoline Engines Using a Multiple Ion Probe2024-32-003504/18/2025
Multiple-ion-probe method consists of multiple ion probes placed on the combustion chamber wall, where each individual ion probe detects flame contact and records the time of contact. From the recorded data, it is also possible to indirectly visualize the inside of the combustion chamber, for example, as a motion animation of moving flame front. In this study, a thirty-two ion probes were used to record flames propagating in a two-stroke gasoline engine. The experiment recorded the combustion state in the engine for about 3 seconds under full load at about 6500 rpm, and about 300 cycles were recorded in one experiment. Twelve experiments were conducted under the same experimental conditions, and a total of 4,164 cycles of signal data were obtained in the twelve experiments. Two types of analysis were performed on this data: statistical analysis and machine learning analysis using a linear regression model. Statistical analysis calculated the average flame detection time and standard
Yatsufusa, Tomoaki, Okahira, Takehiro, Nagashige, Kohei
Technical Paper
Development of Pistons Suitable for Compact Air-Cooled Engines2024-32-003004/18/2025
For the realization of carbon neutrality, we are working on research to improve the thermal efficiency of engines for motorcycles. Friction losses in the cylinder bore account for about 40% of the total friction losses of the engine (Figure 1), which is directly related to thermal efficiency improvement [1]. Air-cooled engines are suitable for motorcycles due to their simplicity and light weight, but it is difficult to achieve both efficiency and reliability. Friction in the cylinder is generated by piston scuffing. The oil film distribution of the piston-skirt(=skirt) is thin at the center of the skirt and thick at the edge. To reduce piston friction, it is effective to make the thin oil film at the center of the skirt thicker. On the other hand, to reduce oil consumption, the oil film must be thinned. However, air-cooled engines, which are difficult to keep the cylinder temperature constant, cannot make the clearance between the cylinder bore and the piston small. An increase in
Suda, Naoyuki, Hihara, Taiki, Ninomiya, Yoshinari
Technical Paper
Experimental Investigation of n-C7H16/Ethanol Blended Fuels on Auto-ignition and Flame Propagation in High Temperature/Pressure Constant-Volume Combustion Vessel2024-32-005004/18/2025
This study aims to investigate the effect of ethanol blends on flame propagation and auto-ignition under high pressure and high temperature conditions. Experimental investigations are conducted using n-C7H16 / ethanol blends at various blending ratios (0, 5, 10, 20, 40, 70, and 100 vol%). The blends are premixed with air at stoichiometric ratios and ignited centrally in a cylindrical constant-volume combustion chamber (20-mm inner diameter, 80-mm long) under elevated temperature (500 K) and pressure (1.0 MPa) conditions. The results show that auto-ignition occurs at an ethanol blend ratio of 10% or less and ceases above 20%. Increasing the ethanol blend to 70% results in a slight change in flame propagation speed, with a noticeable delay at 100%. The pressure measurements show a peak of about 5.6 MPa at a blend ratio of 5%, which gradually decreases with increasing ratios. High-pass filtering reveals the maximum pressure fluctuation amplitude at the 5% blend ratio, indicating increased
Tateishi, Tokua, Yamaguchi, Riki, Shimokuri, Daisuke, Terashima, Hiroshi, Hara, Takaya, Honda, Yuya, Kawano, Michiharu
Technical Paper
Experimental Study of Port Water Injection System on Single Cylinder Diesel Engine Performance and Exhaust Emission2024-32-002504/18/2025
Vehicle emission standards have become more and more stringent and have driven the development of advanced engine design with low-cost emission control technologies. For small diesel engine which is used in three-wheel (3W) passenger and load carrying vehicles, it was major task to improve lower engine rpm torque and performance to comply with stringent exhaust emissions standard as well, especially for Oxides of Nitrogen (NOx) and Particulate Matter (PM) emissions. Bharat Stage (BS) VI emission standards for three-wheel vehicles was implemented from April 2020 onwards in India. Water injection technology has proven advantageous for low-cost solution with Mechanical fuel injection system on small diesel engines, Intake port water injection is the easiest method to introduce water to engine cylinder, which calls for minimal modification of existing engine structure. In the present study 435cc naturally aspirated DI Diesel engine used for three-wheel vehicle was explored by adding water
Syed, Kaleemuddin, Chaudhari, Sandip, Khairnar, Girish, Katariya, Rahul, Jagtap, Pranjal, Bhoite, Vikram
Technical Paper
Effect of Ignition Position on Lean Limit of Main Chamber Combustion in Pre-Chamber Ignition2024-32-002204/18/2025
An engine was built in this study that enabled the conditions in a pre-chamber and in the main combustion chamber to be visualized simultaneously for the purpose of elucidating the mechanism of pre-chamber combustion. An investigation was made of how the state of pre-chamber combustion, including the location of initial flame generation and its subsequent propagation, influenced pre-chamber jet combustion. The state of pre-chamber combustion was intentionally varied by changing the position of pre-chamber ignition. As a result, it was found that changing the position of pre-chamber ignition varied the location where the pre-chamber flame occurred, how the flame propagated and the timing and strength of the flame jet that was ejected into the main chamber. The results revealed that these differences in the state of pre-chamber combustion markedly changed the rate of combustion fluctuation, combustion period, lean-burn limit and other combustion characteristics depending on the ignition
Onuma, Takeru, Yamada, Hiroto, Ugajin, Taisei, Shinozaki, Kaito, Tahara, Ryota, Iijima, Akira
Technical Paper
Studying the Lean Burn Operation in Two-Wheelers to Increase Fuel Efficiency and Investigate the Use of Lean NOx Trap Catalyst (LNT) for Lean Burn System2024-32-005804/18/2025
This study offers an overview of the impact of lean burn technology in two-wheeler vehicles, specifically concentrating on enhancing the fuel economy and addressing the challenges associated with its adoption. Lean burn systems, characterized by a fuel-air mixture with a higher air content than stoichiometric ratio. The study focuses on technology which meets stringent emission standards while enabling the optimization of fuel efficiency. The lean burn system employs strategies to optimize air-fuel ratio using electronic fuel injection, ignition timing control, and advanced engine control algorithms like - updated torque modulation control algorithm for drivability, lambda control algorithm for rich and lean switch and NOx modelling algorithm for LNT catalyst efficiency tracking. The challenges related to lean burn systems, includes issues related to combustion stability, nitrogen oxide (NOx) emissions, and their impact on drivability, is summarized in the study. Mitigation strategies
Somasundaram, Karthikeyan, Sivaji, Purushothaman, John Derin, C, Vishal, Karwa, Manoj Kumar, S, Maynal, Rajesh
Technical Paper
Model-Based Calibration of ECU for Small Motorcycles2024-32-002404/18/2025
To deal with the emission regulations it is necessary to produce ECU control maps that maintain balance of emissions of HC, NOX, CO, engine power output and fuel consumption during the motorcycle development. We have recently introduced the Model-Based Calibration (hereafter as MBC) for calibration of ECU control maps for small motorcycles, which share a big chunk of the market. When introducing we aimed at such a method that can simulate stable temperature conditions necessary for the measurement in order to make it applicable to air-cooled engines predominantly used in small motorcycles. To decrease performance difference between the prototype and the mass-production, the newly developed method allows rewriting of control parameters such as the ignition timing using the mass-production ECU. The fully automated data acquisition along with the application of MBC permits continuous test operations even in nighttime and on holidays. Moreover, the MBC flow was made such a manner that
Fujiwara, Hirofumi, Maruyama, Atsushi, Kasai, Yoshiyuki
Technical Paper
A Concept for Functional Modelling of an E-Bike Powertrain2024-32-001704/18/2025
The increasing popularity of e-bikes, especially pedelecs, has led to a growing interest in consideration of e-bike cycling. To achieve a deeper understanding on the process of e-bike cycling and in particular the effects on the rider it can be instrumental to use simulation methods. In this context, the e-bike drive system and its function are of central importance for e-bikes. Therefore, this work proposes a functional modeling of the powertrain of an e-bike with a mid-drive motor, considering legal constraints and support functionalities. The model incorporates the mechanical transmission between pedals, motor, and crank shaft, allowing for a detailed analysis of the e-bike’s performance. Additionally, the support mechanism is depicted, where an electric motor amplifies the rider’s pedaling torque. The electrical behavior of the motor, energy consumption, and battery state of charge are also integrated into the model. This comprehensive approach aims to provide a generic
Rauch, Yannick, Kettner, Maurice, Kriesten, Reiner
Technical Paper
Experimental Investigations of a Hydrogen Fueled Natural Gas Engine and Ion Current Measurement for Combustion Diagnostics in Pure Hydrogen Operationwith Water Injection2024-32-006504/18/2025
In the ongoing effort to decarbonize energy supply, a notable shift involves the conversion or retrofitting of combined heat and power plants to operate on hydrogen as an alternative to natural gas. In this transformative landscape, extensive research is underway to develop and explore innovative combustion processes for hydrogen-fueled engines, aiming to comprehend and optimize combustion processes concerning both engine performance and emissions. Among the various methods available for monitoring the combustion process and engine control, ion current sensing presents itself as a viable option. A unique feature of this research lies in utilizing the engine's spark plug itself as an electrical sensor, measuring the ion current generated during the flame development and combustion processes. Given the limited research on ion current sensing for hydrogen combustion processes, a series of experiments were conducted and presented in this work. These experiments involved sweeps of water-to
Salim, Naqib, Beltaifa, Youssef, Kettner, Maurice, Loose, Oliver, Weißgerber, Tycho
Technical Paper
Enhancements in Hydrogen Low Pressure Injection on Small Two-Stroke Engines2024-32-004704/18/2025
The use of small 2-stroke crankcase scavenged engines running on hydrogen is very attractive for low power rates, when low cost and compact dimensions are the fundamental design constraints. However, achieving optimal performance with hydrogen fuel presents challenges, including uneven air-fuel mixtures, fuel losses, and crankcase backfiring. This research focuses on a small 50cc 2-stroke loop-scavenged engine equipped with a patented Low-Pressure Direct Injection (LPDI) system, modified for hydrogen use. Experimental results demonstrate performance comparable to the gasoline counterpart, but further optimizations are needed. Consequently, CFD-3D simulations are employed to analyses the injection process and guide engine development. The numerical analysis focuses on a fixed operating condition: 6000 rpm, Wide Open Throttle (WOT), with a slightly lean mixture and injection pressure fixed at 5 bar. A numerical model of the entire engine is set up with the primary objective of improving
Caprioli, Stefano, Schoegl, Oliver, Oswald, Roland, Kirchberger, Roland, Mattarelli, Enrico, Rinaldini, Carlo Alberto
Technical Paper
Optimizing Cooling Circuit Lines in between Batteries and Its Thermal Management Unit2025-01-501703/21/2025
Ensuring uniform coolant distribution in electric buses is crucial for battery performance, longevity, and thermal stability. This study optimizes the battery thermal management system (BTMS) for an 18-m electric bus, addressing uneven coolant flow to battery packs caused by pressure drop variations. One-dimensional (1D) simulations were chosen for their ability to quickly and efficiently analyze flow and pressure variations, providing a fast solution to optimize coolant distribution across the system. dP-Q curves for the BTMS pump and battery packs were integrated into the 1D model based on supplier data, while the flow resistances of other components (pipes, bends) were calculated using KULI software. To correct flow imbalances, pipe diameters were adjusted to increase resistance in over-cooled areas, redistributing coolant to under-cooled sections. This modification resulted in a balanced flow and improved thermal consistency, contributing to longer battery life. Validation showed
Birgül, Çağrı Emre, Meydan, Ömer
Technical Paper
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Information Report
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New Scoop
A-6 Aerospace Actuation, Control and Fluid Power Systems
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null, null
Information Report
QA Test for CSP-70370530202405/15/2024
QA Test
Airlines Electronic Engineering Committee
Journal Article
An eleventh one for CUR-1174PC11-CUR-1174 (Current)04/02/2024
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Flight Simulator Engineering and Maintenance Committee
Information Report
A computational approach to Fretting Wear prediction of Steel Gaskets under Thermo-Mechanical load using Archards wear model2024-26-027301/16/2024
IC Engine is the heart of an automobile. The failure in any component of the engine will directly affect the performance of the vehicle. The gaskets are among the many vital parts of an IC engine that are essential in ensuring appropriate sealing to prevent gas and liquid leakage and maintain optimal engine efficiency. Engines use a variety of gasket types to accommodate various sealing requirements. Among them the exhaust manifold gaskets is one of the critical gasket elements in IC engines which seals between Cylinder head and extremely hot Exhaust Manifold, this prevents the leakage of hot exhaust gasses produced during combustion. The gaskets are crucial components because they endure extremely high mechanical loads from the exhaust manifold sliding and banana-shaped bending brought on by thermal expansion, as well as extremely high thermal loads from the high exhaust gas temperatures, which are around 1000°C. These gaskets are additionally subjected to extremely high bolt loads
Reddy, Rajavardhan, Kulkarni, Sanjeev, R B, Govind, Mueller, Frank Oliver
Technical Paper
3-D Multiphase Flow Simulation of Coolant Filling and Deaeration Processes in an Engine Coolant System2024-26-031001/16/2024
The thermal performance of an engine coolant system is efficient when the engine head temperature is maintained within its optimum working range. For this, it is desired that air should not be entrapped in the coolant system which can lead to localized hot spots at critical locations. However, it is difficult to eliminate the trapped air pockets completely. So, the target is to minimize the entrapped air as much as possible during the coolant filling and deaeration processes, especially in major components such as the radiator, engine head, pump, etc. The filling processes and duration are typically optimized in an engine test stand along with design changes for augmenting the coolant filling efficiency. However, it is expensive and time-consuming to identify air-entrapped locations in tests, decide on the filling strategy and make the design changes in the piping accordingly. In the current effort, a simulation-based testing method for coolant filling and deaeration processes is
Khandagale, Vitthal, Pasunurthi, Shyam Sundar, Maiti, Dipak, Bollu, Theja, Saha, Rohit
Technical Paper
Experimental Study of Piston temperature profile with respect to varying engine parameters – Using Telemetry Method2024-26-034101/16/2024
As emissions standards become more stringent, OEMs are pushing engines to run on leaner fuel mixtures, which puts increased thermal stress on components, particularly pistons, causing them to operate at higher temperatures. This requires more robust design and rigorous testing of components. Telemetry methods offer accurate and real-time feedback, allowing designers to test components at various operating conditions, providing more flexibility than other traditional methods. Piston temperature measurement is a critical aspect of engine development because it directly affects engine performance and durability. Among the various techniques available for this purpose, telemetry methods have gained considerable attention in recent years. This method involves integrating temperature sensors and transmitter on the piston, which transmit temperature data wirelessly to a receiver outside the engine. In this paper, we evaluate the impact of coolant temperatures, valve timing, ignition timing
Pandey, Ram Krishan, KUMAR, ATUL, Jangra, Sumit
Technical Paper
Development of 8L Hydrogen IC Engine2024-26-017001/16/2024
Throughout the world the efforts are being carried out to reduce the GHG emissions from transportation sector. As Volvo Group is a signatory of SBTi and having internal target of Carbon neutrality by 2040, we have intensified & also diversified our R&D efforts to develop powertrains of the future having mix of conventional, various alternate fuels, electric etc. There will not be a unique solution or strategy suiting for all the markets in the world. Each market will have its own motivation & factors which OEMs need to consider while deciding the short term, midterm & long-term strategy for powertrain technology. Accordingly, OEMs must be ready with product mix suitable for all global markets. This paper will talk about the efforts taken and lessons learned during development of Hydrogen fueled IC Engine. We used 8L Diesel IC engine as a base to convert it to Hydrogen powered IC engine, in a retrofit spirit, so that with minimum changes we could make the working prototype. This engine
LAD, MAKRAND RAJENDRA, Neveu, Jean Marc, S, ANOOP KRISHNA
Technical Paper
Automotive EMC Analysis of Touch Sensing IC2024-26-035301/16/2024
The technology in the automotive industry is evolving rapidly in recent times. Thus, with the development of new technologies, the challenges are also ever-increasing from an Electromagnetic Interference and Susceptibility (EMI/EMC) perspective. A lot of the latest technologies in Adaptive Driver Assistance Systems (ADAS), which include Rear Drive Assist, Blind Spot Detection (BSD), Lane Change Assist (LCA) to name a few, and other features like Anti-Braking System (ABS), Emergency Brake Assist (EBD) etc. rely heavily on different types of sensors and their detection circuitry. In addition, a lot of other internal functions in the Engine Control Unit (ECU) also depend on such sensors’ functionalities. Thus, it becomes imperative to study the potential impact of higher field emissions on the immunity behaviour of the sensors. In this paper, we will study the immunity behaviour of such an automotive capacitive touch-sensing integrated circuit (Microcontroller IC) and its impact on the
Boya, Vinay Kumar, Adhyapak, Anoop, Komma, Vineetha, sahoo, Manoranjan
Technical Paper
Optimization of Cooling Air Flow for improved Heat Dissipation through Radiator.2024-26-004201/16/2024
Optimization of Cooling Airflow for improved Heat Dissipation through Radiator Authors: Paurnima Thakur, Amit Aher, Vishal Chavan, Chandrakant Palve Mercedes-Benz Research and Development India Private Limited Key Words: Radiator, Temperature, Heat Dissipation, Airflow, Cooling, Thermal Efficiency Abstract: Heat regulation is indispensable factor during operation of internal combustion engine. Automotive engine cooling system takes care of excess heat produced during engine operation. It regulates Engine surface temperature for engine optimum efficiency and plays important role in meeting CO2 emission target set by Environmental Protection Agency (EPA). Insufficient heat dissipation results into Engine overheating. This will affects thermal efficiency & ultimately brake specific fuel consumption of the Internal Combustion Engine. Radiator is the central component of a vehicle cooling system to monitor and regulate engine temperature and prevent it from overheating. Heat dissipation
Palve, Chandrakant, Thakur, Paurnima, Chavan, Vishal, Aher, Amit
Technical Paper
OIL AEROSOL EMISSION OPTIMISAITON IN HIGH POWER DIESEL ENGINE USING DEFLECTORS IN TURBO CHARGER OIL DRAIN CIRCUIT2024-26-004701/16/2024
Closed crankcase ventilation prevent harmful gases from entering atmosphere thereby reducing hydrocarbon emissions. Ventilation system carries blowby gases leaking through combustion process along with oil mist to Engine intake system. Major sources of blowby often occurs from leak in combustion chamber through piston rings, leaks from turbo shafts & valve guides. Oil mist carried away by blowby gases gets separated using filtration media. Fleece type separation media has high separation efficiency for particles above 10 microns. Efficiency drops if mist particle is below 10-micron size. Low size aerosol mist generally forms due to flash boiling on piston under crown area and on shafts of turbo charger due to high speeds combined with elevated oil temperatures. High power density diesel engine is taken for our study. It produces low particle size oil mist which contributes to aerosol emission of 3 gm/hr when operated at rated speed. Particle size measurement done using light refraction
M, Velshankar, Dharan R, Bharani, DHADSE, ASHISH, Permude, Ashok, Loganathan, Sekar
Technical Paper
Prognosis of engine failure based on modelling by using live parameter data from vehicle.2024-26-026601/16/2024
Predicting engine failure upfront to prevent major damages is a challenging task. But with the data available from the ECU (engine control unit) transmitted live via the telematics unit provides a data base to predict the health of engine and its major sub system. Through proper data analytics using the logics arrived based on previous / tested data the possibility of failure occurrence and the corrective action required to avoid the same can be indicated. This paper aims at an application with Modelled data analytics to analyze the live parameter data and apply predefined logics to predict engine / sub system level health and possible occurrence of a failure. Vehicle data was used to predict the engine / sub system failures. Application using PHYTON was developed to evaluate the severity of application duty cycle on engine and also to evaluate the health of major sub system. The logic and modelling was verified on field vehicle data and the application was able to predict the failure
K.S, Guru Prasanna, D.V.Ramkumar, D.V.Ramkumar, kannan. s, S.Kannan, Karthikeyan, K.R.Karthikeyan, Suprabhan.S.P, S.P.Suprabhan, Narayana Reddy.J, J.Narayana Reddy, Augustin Selvakumar, Augustin Selvakumar, Senthilkumar.M.D, M.D.Senthilkumar, Somsekar.D, D.Somasekar
Technical Paper
Development of System Level Testing Method for Passenger Car Engine Mounts2024-26-032401/16/2024
Engine mount is an integral part of any Internal Combustion engine. It is the medium which isolates the vibrations coming from engine being transferred to the chassis or body of vehicle. Engine or power plant is the main source of unbalanced vibrations. The major role of an engine mount is to minimize those vibration levels, improve ride comfort and increase the life of an engine and its accessories. Most of the OEM’s are validating the engine mounts in virtual environment as FEA analysis software. In this paper detailed procedure of testing of Engine mount at system level is presented. This work determines the development of test procedure for passenger car engine mounts in the Laboratory by using Multi-axial environment which also explains the details of truly Multi-axial test rig development, Drive file creation and Durability Testing with the maintained vehicle conditions by simulating the field conditions in the laboratory. Results of simulation and durability also enclosed. This
Tormal, Uday Bapurao
Technical Paper
Thermal Performance Prediction of Roots blower Using Coupled 3-D Multiphase CFD Thermal simulation with Experimental Validation2024-26-029701/16/2024
Abstract Roots blower is a rotary positive displacement pump which operates by pumping a fluid with a pair of meshing lobes. Recent trends in automotive industry demands high power density solutions for various applications. In comparison with legacy applications, compressors for high power dense applications demands more continuous operation with harsher duty cycle, demanding higher pressure ratios. Because of longer duty cycles, it will be subjected to high heat loads which will cause a rise in temperatures of timing gears, bearings, and other components within assembly. Accurate prediction of thermal performance is critical to design a durable and efficient roots blower for high power density applications. Thermal analysis of an assembly of roots blower involves modelling of multi-physics. This paper details a coupled CFD analysis approach to predict temperatures of roots blower components and timing gear case oil. Timing gears are lubricated using wet sump lubrication. The oil
C, Anandha krishnan, Jambare, Giridhar, Raut, Nikhil, Niranjan, Bhanupratap
Technical Paper
Integrated Simulation Methodology to Predict Engine Head, Block, and Piston temperatures.2024-26-031501/16/2024
With the constant strive towards increase in performance and corresponding stringent emission standards of modern IC engine, engine components such as the head, block and piston are subjected to higher thermal loads. This is why it is important to mitigate failures early in the design cycle of any engine program. An integrated simulation methodology is proposed where the head, the block and the piston are integral part of the analysis. The CFD – CHT methodology is used to simulate and predict the temperature of these engine components. The head and block are run in a steady-state conjugate heat transfer framework while the transient multiphase volume of fluid (VOF) approach is used to predict piston temperatures. Combustion surfaces boundary conditions are derived from 3D CFD open-loop combustion simulation, while cooling and lubrication surface boundary condition are mapped from 1D system simulation or experimental data. The heat transfer boundary conditions are swapped between the
Sahu, Abhay Kumar, CHAKKAMADATHIL, SHIRDI, Das, Debasis
Technical Paper
Optimizing Closed Loop Air Mass Control in Naturally Aspirated Engines: A Differential Pressure Sensor Approach to meet BS6 Emission Norms2024-26-014701/16/2024
In order to meet stringent emission targets and to achieve better fuel efficiency, closed loop air mass control strategies have become essential across all vehicle segments. Closed loop air mass control mandates measuring fresh air mass entering the engine combustion chamber. However, in Naturally Aspirated (NA) engines, while measuring air mass using conventional methods such as Hot Film Air mass (HFM) sensor, heavy pulsations in the Air-intake results in errors which would impact closed loop air mass control and lead to inconsistencies in emissions. To address this issue, we studied different approaches using HFM sensor with Resonator, differential pressure sensor across the intake air filter and Lambda based air mass control. Based on this empirical study we found that modelling air mass with differential pressure sensor using Bernoulli’s principle (Flow rate ∝ √Differential pressure) results in higher accuracies compared to conventional methods. This solution gives accurate, cost
Y, Pavan, Shanmugam, Balaji, R, Rachana
Technical Paper
Enhanced impeller blade design for water coolant pump in IC engines2024-26-003401/16/2024
Enhanced impeller blade design for water coolant pump in IC engines Sudeshna Roy Pratihar, Amol Barve, Onkar Mokashi, Naveen Patil Mercedes-Benz Research & Development India Private Ltd, India. Keywords: Turbulence; hydraulic efficiency; friction loss; computational fluid dynamics; tubercles Abstract: This paper illustrates scope for improvement in water pump hydraulic efficiency by proposing novel design of impeller blade for internal combustion engine. For water pump, hydraulic efficiency is directly proportional to fluid drag imposed on impeller blades. Friction loss & turbulence during typical operating conditions needs to considered, by keeping in mind optimum performance of water pump. Increase in drag losses results in higher power consumption of water pump. Considerable literature study indicates that, tubercles design in area of IC Engines more precisely in topics relevant to water pump design has never tested for Automotive application. Extensive analytical calculation
Barve, Amol, Roy Pratihar, Sudeshna, mokashi, Onkar, Patil, Naveen
Technical Paper
Weight and Drivetrain optimization via Fuel pump & Vacuum Pump drive by engine camshaft in a pushrod type valve actuated engine.2024-26-004601/16/2024
Optimizing weight, cost and friction is critically focused in most modern powertrains. Lesser components in drive trains makes the systems` lightweight and more efficient. This paper explains the idea of integrating a fuel pump and a vacuum pump drive system on to the main camshaft eliminating many rotating & static parts in a two valve per cylinder push-rod type actuated 4-cylinder diesel engine, thereby reducing overall weight, cost and drive losses. The modified camshaft will now drive oil pump, vacuum pump, fuel pump and valve train together. The existing camshaft is extended with a slot at one end and a three lobed cam made of higher grade material is press fitted on to the said portion with an additional journal bearing face added. Proposed camshaft design is evaluated for handling higher power transmission considering multiple drives are connected. Design verification simulations are run including High cycle fatigue, camshaft bearing EHD, Timing drive dynamics to ensure all
John, Shijino Shaji, Sasikumar, K
Technical Paper
Experimental And Numerical Investigation of a Single-Cylinder Methanol Port-Fuel Injected Spark Ignition Engine for a Heavy-Duty Applications.2024-26-007201/16/2024
With the increasing focus on reducing CO2 emissions to combat global warming and climate change, the automotive industry is exploring near zero-emission alternative fuels to replace traditional fossil-based fuels like diesel, gasoline, and CNG. Methanol is a promising alternative fuel that is being evaluated in India due to its easy transportation and storage, as well as its production scalability and availability potential. This study focuses on the retro-fitment solution of M100 (pure methanol) SI port-fuel injection (PFI) mode of combustion. A heavy duty single-cylinder engine test setup was used to assess methanol SI combustion characteristic. Lean operation strategy has been investigated. At lean mixture conditions a significant drop in NOX and CO emissions was achieved. The fuel injection techniques and the impact of exhaust gas recirculation (EGR) on the conventional stoichiometric combustion process is highlighted. Increase of the EGR ratio at stoichiometric operation led to 3
Singh, Inderpal, Güdden PhD, Arne, Raut PhD, Ankit, Emran, Ashraf, Dhongde PhD, Avnish, Sharma, Vijay, Wagh, Sachin
Technical Paper
An optimum solution to meet the Thermal load challenge in a high mobility military vehicle2024-26-024601/16/2024
Military vehicles are intended to operate at rugged terrains in adverse environmental conditions. Unlike a regular truck, these vehicles are powered by a much bigger engine and transmission to meet the vehicle performance parameters. Thermal systems in these vehicles are challenging. With the adverse climatic condition and driving terrains, the criticality of Engine cooling system are intensified. In this paper, a Cooling system is finalised for a high mobility military vehicle with high power engine, Automatic transmission and a hydraulic retarder. Thermal load cases are different for each. Modelling is done in thermal simulation software KULI. A steady state simulation is done for engine and automatic transmission. Transient simulation is performed for retarder. The aim is to finalise a cooling system circuit consisting of radiator, oil to air cooler and oil to water cooler which are interconnected to meet the heat load demand of engine, transmission and retarder together.
AT, SHAJAHAN, KIRAN, NALAVADATH, RAO, BONTHALA
Technical Paper
Predictive Underhood Thermal Management Model2024-26-027201/16/2024
In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the
P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR
Technical Paper
Refined Driveline Isolation in Bus Vehicles2024-26-020501/16/2024
Bus vehicles required isolated NVH performance at the mounting of the Engine, Propeller shaft, AC Compressor, etc. within a relative package envelope. This paper demonstrates the most predominant NVH case in Bus vehicles in which aggregates are mounted on the chassis Frame and its attachment point stiffness and mobility in multi directions are studied. The same was evaluated analytically and tested so as to cater to NVH issues in vehicles. Also, it contains the details of the systematic approach used with the help of digital software by creating the analytical model so as to resolve issues of multi-direction high mobility and relatively low stiffness at the attachment points. This evaluated model can be used across similar application vehicles so to avoid multi-iteration design and development costs. Digital Analysis indicates a good correlation with the tests for specific loading conditions. Multiple solutions were studied that were confirmed in the analysis. The most cost-effective
Dhadiwal, Nishant Surendra, Pathak, Rahul, Bijwe, Vilas, Gore, Pandurang
Technical Paper
Design optimization of Engine Mount bracket to reduce various gear noises in the passenger car cabin2024-26-020801/16/2024
With the advancement of regulatory norms in the automobile industry, there is challenging to meet performance efficiency targets, especially with a lightweight platform, while providing a superior driving experience to customers. The shift towards weight optimization makes the vehicle structure more susceptible to transfer a diverse range of noise and vibrations through the body. Although most undesirable noises perceived inside the cabin can be reduced by superior technology engine mounts and NVH packaging, all such solutions lead to cost addition. Intelligent considerations in part design can be used to supplement predictable transfer paths to quell unwanted vibrations. One such case is of the gear whine noise in certain rpm bands caused by inherent gear meshing frequency coinciding with the natural frequency of an engine mounting bracket. This paper demonstrates two methodologies to counter such a phenomenon, either through engine mount bracket natural frequency optimization or
Ghosh, Chiranjit, Agrawal, Adheesh, Karmakar, Sudipto, Srivastava, Shubham, Khan, Aamir
Technical Paper
A mechanism to maintain negative crankcase pressure in a turbocharged gas engine to meet Euro-VI emission regulation and to reduce oil consumption.2024-26-014501/16/2024
Emissions regulation continually drives the automotive industry to innovate and develop. This pushes to introduce mechanism to maintain negative crankcase pressure in gas engine to meet this changing regulation. The way a turbocharger is used, to meet engine performance, can impact the pressure balance over the compressor and turbine end seals. This pressure difference can allow oil to leak through turbocharger seals. In normal engine operating condition, the pressure in the turbocharger end housings is higher than the bearing housing and oil/gas flows into the bearing housing, through the oil drain to the crankcase. Under certain operating conditions, such as low idle and thermal management, this pressure difference can be reversed with a higher bearing housing pressure than the pressure behind the turbine compressor wheel. Under this condition oil/gas will flow out of the bearing housing to the recess behind the compressor wheel. The bearing housing pressure will always track the
R, MAHESH BHARATHI
Technical Paper
An experimental approach to investigate the FEAD cover failure & its design optimization.2024-26-037101/16/2024
In automotive Front End Accessory Drives (FEAD), the crankshaft supplies power to accessories like alternators, pumps, etc. FEAD undergoes forced vibration due to crankshaft excitation, dynamic tension fluctuations can cause the belt to slip on the accessory pulleys. By considering the criticality of the system, when engine mounting is longitudinally to the vehicle which makes it directly exposed to the air flow containing foreign particles which may cause the damage to the FEAD system and deteriorate the intended functionality. FEAD cover is introduced in the system to enhance belt-pully system functionality by restricting the entry of foreign particles during engine operation. This paper contains study of FEAD cover failure and provide the stepwise approach to capture such issue during novel model development for 4 cylinder naturally aspirated engine during engine bench testing. Failure mechanism was studied using various methodology such as CAE and G-Load measurement to identify the
PATEL, HARDIK MANUBHAI, KUMAR, NITISH, Chand, Subhash, Gupta, Vineet
Technical Paper
USUALLY UNOBSERVED REFINEMENTS OF AUTOMOBILE CONSTRUCTION08000301/01/2024
ELLSWORTH, JOHN MAGEE, FAY, THOMAS J.
Technical Paper
test download manager cache issue 12/27/2023 at 9 amSAE-PP-0908512/27/2023
test download manager cache issue 12/27/2023 at 9 am
Mutagaana, Festo
Pre-Print Article
Research on the Secondary Motion of Engine Piston Considering the Transport of Lubricating Oil03-17-03-002411/21/2023
Abstract At present, it is generally considered in the analysis of the secondary motion of engine piston that the piston skirt–cylinder liner friction pair is fully lubricated in an engine operating cycle. However, in practice, when the piston moves upward, the amount of lubricating oil at the inlet may not ensure that the friction pair is fully lubricated. In this article, the secondary motion of piston is studied when the transport of lubricating oil is considered to determine the lubrication condition of piston skirt–cylinder liner friction pair. The secondary motion of piston is solved based on the combined piston motion model, hydrodynamic lubrication model, asperity contact model, and lubricating oil flow model. The secondary motion equation of piston is solved by the Broyden method. The hydrodynamic lubrication equation is solved by the finite difference method. The asperity contact between piston skirt and cylinder liner is calculated by the Greenwood model. The flow of
Liu, Jihai, Sun, Jun
Journal Article
Regression 11/1/23SAE-PP-0892211/01/2023
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Mutagaana, Festo
Pre-Print Article
Simulation Study on EGR Condensate Flow and Uniformity of Each Cylinder in the Intake Manifold2023-01-703410/30/2023
As engine technology developed continuously, engine with both turbocharging and EGR has been researched due to its benefit on improving the engine efficiency. Nevertheless, a technical issue has raised up while utilizing both turbocharging and EGR at the same time: excess condensed water existed in intake manifold which potentially trigger misfire conditions. In order to investigate the root-cause, a CFD model (conducted by CONVERGE CFD software) was presented and studied in this paper which virtually regenerated intake manifold flow-field with EGR condensed water inside. Based on the simulated results, it concluded that different initial conditions of EGR condensed water could significantly change the amount of water which deposited in each cylinder. Thus, a coefficient of variation of deposited condensed water amount among these cylinders, was marked as the evaluation reference of cylinder misfire. Theoretically, as this coefficient of variation reduced, the EGR condensed water from
Pan, Shiyi, Li, Guanting, Wang, Jinhua, Zhang, Nan, Xu, Zhiqin, Chen, Shanghua, Chen, Jun, Zhao, Shengwei
Technical Paper
Research on Injection Characteristics of Marine Ammonia Fuel Injector under Wide Temperature Range2023-01-701710/30/2023
Ammonia fuel is typically characterized by low viscosity, low flash point, and non-flammability. This means that fuel characteristics and operational requirements significantly deviate from those of conventional fuels, requiring a significant technical upgrade to the existing fuel supply and injection systems. This research involves a numerical analysis of ammonia utilization in high-pressure direct injection. Considering the non-isothermal compressibility of the fuel flow process, the fluid properties in the model are specifically defined based on the physical properties of the ammonia fuel. The injection performance of ammonia fuel was studied, including comparing the injection performance of ammonia fuel with conventional diesel fuel under typical operating conditions in the injector, and exploring the injection characteristics of ammonia fuel injector under a wide fuel temperature range. The results of ammonia injection indicate that the response characteristics of liquid ammonia
Li, Meisi, Fan, Liyun, Wei, Yunpeng, Mao, Yuntao
Technical Paper
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