Browse Topic: Valve covers

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Ignition System Measurements ProcedureJ973_202011 (Historical)11/3/2020
This SAE Recommended Practice specifies the design and/or evaluation with the specific equipment, conditions, and methods for distributorless battery ignition systems intended for use in various internal combustion engines including automotive, marine, motorcycle, and utility engine applications. The test procedures listed in this document are limited to measurements performed on a test bench only and do not include measurements made directly on engines or vehicles. This standard is not intended to supply information for battery ignition systems used in aircraft applications of any type.
Ignition Standards Committee
Optimum Positioning of FIP Drive System for Type-II BSVI Engine Based on Coupled 1D “Valve-Train - Chain Drive Dynamic Analysis2020-01-10204/14/2020
The automotive industry is gearing up to meet the accelerated emission compliance changes posed by the government. This transition to eco-friendly system would also necessitate an automotive engineer to retain the engine packaging as compact and simple as possible. The packaging layout considered should not be at the expense of deteriorating engine performance. The work started with concept level layout development, with the aim of having simplified system with minimum number of components. The engine on which the work was carried out was 4cylinder 3Liter with OHC configuration A number of layouts were developed which included gear type, belt drive and integrated shaft arrangement for driving FIP. Each of these concepts were brainstormed with its advantages and disadvantages, based on which two concepts were initially proposed for driving FIP system (i) Front Driven FIP (ii) Rear Driven FIP. The difference between the two layouts was that in the latter case the FIP system was directly driven through exhaust camshaft with gear type arrangement. For the above two proposed layouts, dynamic evaluation was done up-to max intermittent speed of engine by modeling complete valve-train system along with chain drive in AVL Excite timing drive. The Excite timing drive model dynamic results showed that with the rear layout FIP system, the valve-train along with chain drive system was getting heavily loaded demanding more robust design leading to an unintentional increase in system mass. For further visualization of the two layouts, engine level testing was done by developing proto parts for both the concepts and the conclusive results were found to be in-line with the simulation results.
Kaundabalaraman, Kaarthic, Rathi, Hemantkumar, Bisht, Jasvir Singh
Engineering the 2020 CHEVROLET CORVETTE19AUTP09_019/1/2019
The eighth-gen (C8) Corvette is a creative mix of novel and traditional technical solutions unleashed at a shockingly low base price. Two days before the 50th anniversary of astronaut Neil Armstrong's leap for mankind and 10 years after General Motors emerged from bankruptcy, the camouflage was finally ripped from the eighth-generation (C8) 2020 Chevrolet Corvette. As widely anticipated, C8 now flaunts a mid-engine layout that ostensibly puts it on equal terms with the world's most venerated supercars. After six decades of experimentation and concept-car teasing, GM acknowledged that the new Stingray will enter production before year's end. The truly shocking announcement is a base price of $59,995 including destination, only $3,000 more than today's front-engine C7. Along with moving the cockpit forward 16.5 inches (419 mm) to facilitate shifting the engine rearward, the new Corvette is an innovative mix of novel and traditional engineering solutions.
Sherman, Don
Blocked Force Determination on Thin Plate Structures Including Applications2019-01-15256/5/2019
Transfer path analysis is commonly used to determine input forces indirectly utilizing measured responses and transfer functions. Though it is recommended that the source should be detached from the vibrating structure when measuring transfer functions, engineers and technicians frequently have a difficult time in doing so in practice. Recently, a substitute for inverse force determination via transfer path analysis has been suggested. The indirectly determined forces are termed blocked forces and are usable so long as the source and machine are not detached from one another. Blocked forces have the added advantage of being valid even if the machine structure is modified. In this research, a typical automotive engine cover is considered as a receiver structure and is bolted to a plastic source plate excited by an electromagnetic shaker. Blocked forces are determined at different locations, and the correctness of the calculated blocked forces is assessed by comparing the predicted and simulated responses at selected receiver points which were not used for determining the blocked forces.
Chen, Keyu, Herrin, David
Design and Development of a Roller Follower Hydraulic Lash Adjustor to Eliminate Lash Adjustment and Reduce Noise in a Serial Production Diesel Engine2018-01-17669/10/2018
Commercial vehicles require continual improvements in order to meet fuel emission standards, improve diesel aftertreatment system performance and optimize vehicle fuel economy. Aftertreatment systems require significant space claim which makes vehicle packaging a challenge. Today’s diesel engines require valvetrain lash adjustment settings at distinct intervals to ensure proper valvetrain performance. This requires removing the engine rocker cover to access the valvetrain rocker arms for setting lash. Setting lash for compact vehicle applications sometimes requires removing the aftertreatment system to provide access to the rocker cover prior to setting lash. Then, the rocker cover is reinstalled followed by the aftertreatment system making the lash setting process time consuming and complex. This paper focuses on the design, development and validation of adapting hydraulic lash adjusters (HLAs) into a type V (camshaft in block) diesel engine thus eliminating the lash adjustment process. The flat mechanical tappets were replaced with roller follower HLAs on both the intake and exhaust valves. The roller was included to reduce valvetrain friction over flat tappets. An anti-rotation design was included to maintain alignment between the roller and the camshaft. A major advantage of using the HLA was reduced engine valvetrain noise. Minor engine block changes were required to accommodate the roller follower HLAs. The HLA design ensured reliable and repeatable valve motion from engine build thru cold start and normal engine operation over the useful life of the engine. Reliability was key for the roller follower HLA as it is embedded inside the block which makes replacement impractical. This paper highlights the major design aspects for including roller follower HLAs in a type V diesel engine.
Roberts, Leighton, McCarthy, Jr., James
International develops new, lighter A26 engine to replace N1317TOFHP04_104/1/2017
Any time a new engine is announced, it is major news. Pairing a new engine with a new approach to engine development is even bigger news. International Truck recently unveiled its all-new engine for the Class 8 market: the International A26. Along with that came news of an initiative called Project Alpha, which brought together a small team of powertrain engineers dedicated to a new perspective on engine development. “The A26 was designed from the ground up to deliver industry-leading uptime, durability and reliability,” said Darren Gosbee, vice president of advanced engineering. The 12.4-L A26 sources a MAN D26 inline 6-cylinder crankcase from their partnership with the Volkswagen Group and surrounds it with numerous all-new components to optimize four key criteria: uptime, fuel efficiency, weight and NVH (noise, vibration and harshness).
Borst, Matthew
Engine Noise Reduction Using Self-Tuning Torsional Vibration Damper2016-01-10634/5/2016
Up to 30% of engine noise is delivered by front end pulley combined with torsional vibration damper, and technically it is the main contributor to recorded engine noise level. So the novel solutions in terms of improving the design and performance of torsional vibration damper would help to reduce radically this component of engine noise. The results of dynamical study of patented torsional vibration damper combined with pulley are presented. Design and structure of torsional vibration damper is based on author’s US Patent 7,438,165 having the self-tuning control system for all frequencies in running engine in all operational regimes. Mathematical model has been used for the analysis of the emitting noise of engine having proposed torsional vibration damper. Attention is paid to mitigation of the sound power levels contributing by engine subsystem “end of crankshaft - torsional vibration damper - pulley”. Theoretical analysis reveals that the proposed self-tuning torsion damper could nullified the vibration (and, consequently, the noise) consisting of components having up to 9 frequencies. Tests have been conducted in order to get the objective metrics and compare the noise performance of engine completed with new device to data when engine have a conventional torsional vibration damper. The tested engine demonstrated 5.4 dB(A) improvement of overall noise levels due to usage of proposed self-tuning torsional vibration damper.
Nerubenko, George
Transfer Path Analysis: Accurate Load Prediction beyond the Traditional Mount Stiffness and Matrix Inversion Methods2014-36-079911/4/2014
The source-transfer-receiver model to approach automotive NVH problems has proven its worth over the last decades. The approach allows splitting up an NVH problem into a source, for example engine vibration or road induced wheel vibration, a transfer system, for example the car body or car suspension, and a receiver such as the driver ear or steering wheel feeling. The analysis of such a system is called Transfer Path Analysis (TPA). Whereas the determination of the transfer system for a TPA analysis through frequency transfer functions or a set of modes is fairly straightforward, the source side can pose quite some difficulties. For the sake of this paper, the sources are defined as the forces acting on the body structure of a car through the engine (for an engine noise problem) or suspension mounts (for a road noise problem). The traditional way to determine these forces is through the use of the so-called mount stiffness method for soft mounts and the matrix inversion method for stiff mounts. Both methods work well in most cases. Both do have their limitations though. The mount stiffness method requires the availability of the (frequency dependent) mount stiffness which is not always the case and the matrix inversion method depends highly on the condition number of the FRF matrix and requires extensive test efforts. This paper will therefore review 2 additional TPA methods that add additional load identification methods to the portfolio: operational TPA (or OPAX) which besides being a fast method requiring less instrumentation, also alleviates the need for detailed mount data for soft mounts, and Strain-based TPA which allows the determination of closely coupled forces that would otherwise result in an ill-conditioned matrix inversion problem. OPAX simplifies the measurement effort need for TPA analysis and identifies the mount stiffness's as part of the path identification process using a parametric model. It is shown in this paper that the method is fast and works well in identifying the dominant path contributions to a noise problem. Strain-based TPA uses strain sensors, rather than acceleration data, as response locations for matrix inversion. The advantage being that, whereas accelerations capture global deformation patterns very well, the strain sensors will be much more sensitive to local effects. A number of industrial scale applications will illustrate the methodologies and demonstrate the added value compared to classical TPA.
Dom, Steven, Geluk, Theo, Janssens, Karl, Van der Auweraer, Herman
X-ray Imaging of Cavitation in Diesel Injectors2014-01-14044/1/2014
Cavitation plays a significant role in high pressure diesel injectors. However, cavitation is difficult to measure under realistic conditions. X-ray phase contrast imaging has been used in the past to study the internal geometry of fuel injectors and the structure of diesel sprays. In this paper we extend the technique to make in-situ measurements of cavitation inside unmodified diesel injectors at pressures of up to 1200 bar through the steel nozzle wall. A cerium contrast agent was added to a diesel surrogate, and the changes in x-ray intensity caused by changes in the fluid density due to cavitation were measured. Without the need to modify the injector for optical access, realistic injection and ambient pressures can be obtained and the effects of realistic nozzle geometries can be investigated. A range of single and multi-hole injectors were studied, both sharp-edged and hydro-ground. Cavitation was observed to increase with higher rail pressures. Comparative analysis of several injectors indicates that rounding the nozzle inlet delays the onset of cavitation due to reduced separation, but does not always suppress it. Tapering the nozzle hole is an effective means of suppressing cavitation. A single-hole injector mesh was designed based on x-ray imaging, and high resolution three dimensional large eddy simulations were performed using a homogeneous relaxation model. A two-phase submerged simulation was compared against a three-phase compressible solver modeling both non-condensible ambient gas and cavitation. Projections showed good agreement between the three-phase solution and x-ray experiments.
Duke, Daniel, Swantek, Andrew, Tilocco, Zak, Kastengren, Alan, Fezzaa, Kamel, Neroorkar, Kshitij, Moulai, Maryam, Powell, Christopher, Schmidt, David
Rapid Design and Development of Noise Radiating Engine Components2014-01-16814/1/2014
This paper describes the rapid design and development of thin walled powertrain components which act as external cover for engine subsystem assemblies. Computer Aided Engineering plays a major role in reducing the overall product development lead time. An approach by using ‘Simulation Driven Design and Development’ helps the developers to bring the necessary confidence about the components' required functionality during the design stage itself. During the design stage, typical inputs available for the development of these components are the broad dimensions obtained from the packaging considerations. The designer is required to develop the concepts targeting least noise radiation from component surfaces due to various excitations. Based on cost considerations, the designer can even opt for plastic materials instead of steel. The current paper considers two major noise radiation members namely valve cover and timing gear cover for rapid product development. A conventional modal analysis followed by harmonic response studies provides the basis for the iterations towards designing these members. The modal analysis, harmonic response studies and noise radiation efficiency calculations are performed by using a commercial FEA program. It is observed that the suggested Simulation Driven Design and Development approach has reduced the development time from 2 months to 3 weeks for the design finalization.
Shanmugam, Manivasagam, Kharatmal, Raghavendra, Satpute, Shirish
Design and Development of Cylinder Block for High Power Density Diesel Engine using CAE/CFD Tools for a Tractor Engine with Integrated Approach2013-01-275311/27/2013
Engine Block, being the most vital component requires serving various functions all together. Design of block for higher power densities and BMEP levels, needs a complete change in the design strategy compared to the existing design approach. Also, balancing other factors like engine cooling efficiency, blow by targets, weight, and manufacturing cost becomes a huge challenge upfront in designing an engine block. Design of block is carried out within several design, assembly and manufacturing constraints such as to maintain a specific cylinder centre distance, Block NVH, Better cooling jacket, controlled bore deformation and incorporation of various accessories viz. CRDI System, Fuel Filter, Oil Filters, Fuel Injection System, steering pump, Air Compressor etc. This paper portrays the complete perspective and design methodology used during design process. Integration of classical methods, and FE analysis is presented. FE analysis is mainly carried out for understanding bore deformation, stress flow path and cylinder head gasket pressure distribution. CFD analysis helped in optimizing the cooling jackets for a better thermal efficiency. Tools like DFMEA, DFMA etc are used along with value engineering concepts to make an efficient and cost effective product development process. Simulation results are elaborated to show the effectiveness of an integrated approach used in this development program. The simulation tools have helped us in selecting the right parameters for the design and ensure the rightness at the first development.
Dharan R, Bharani, Goud, Raghu Ram, manoharan, Rajkamal, Dhiman, Vikas
Piston Cleanliness via Fuel Additive Technology2013-24-01019/8/2013
This work compared the piston deposit ratings in an engine when it was run on gasoline with a high concentration of deposit control additive (DCA) versus gasoline with a low concentration of additive. The additives came from different sources and contained detergents with different functional groups. The engine was a Ford V-8 PFI engine, which is used in ASTM D6593, the Sequence VG test. The experimental procedure followed the ASTM protocol, except for the fuel, which was treated with additives. Deposit ratings were better, at 95% confidence, in the tests using a high concentration of additive versus the tests using a low concentration.
Mengwasser, John H., Macias, James, Nelson, Edward
Design Strategies for Development of a Series of Small Power Diesel Genset Engines for Future CPCB II Genset Emission Norms2013-26-01321/9/2013
Small power diesel engines are most demanding product in Indian market for stationary applications like power genset, agricultural purpose etc. The upcoming 2013 CPCB emission norms for diesel genset engines below 19 kW power rating are the most stringent one in the world. There is a need not only to upgrade technologies pertinent to the latest emission norms but also to reduce the product cost. This paper presents various design strategies used to meet the desired engine performance and emission levels for development of a series of small power diesel genset engines having bore dia. ranging from 76 mm to 120 mm. Design and development of single and two cylinder NA diesel engines has been carried out with the help of CAD/CAE, design analysis tools, in-house developed algorithms and available statistical database Simulation codes are used for design analysis of engine subsystems like valve train, power train and flow analysis of air cooled engine in order to make the product technically and economically viable. Design verifications performed on several engine systems and sub-systems have been presented in the paper
Tikar, S. S., Marathe, A. V., Mulik, R. V., Ramdasi, S. S., Marathe, N. V.
360° vs. 270° vs. 180°: The Difference of Balancing a 2 Cylinder Inline Engine: Design, Simulation, Comparative Measurements2012-32-010610/23/2012
Beside the automotive industry, where 2-cylinder inline engines are catching attention again, twin-cylinder configurations are quite usual in the small engine world. From stationary engines and range-extender use to small motorcycles up to big cruisers and K-Cars this engine architecture is used in many types of applications. Because of very good overall packaging, performance characteristics and not least the possibility of parts-commonality with 4-cylinder engines nearly every motorcycle manufacturer provides an inline twin in its model range. Especially for motorcycle applications where generally the engine is a rigid member of the frame and vibrations can be transferred directly to the rider an appropriate balancing system is required. A 360° parallel twin engine does generate both: free 1st order mass forces and free 2nd order mass forces. 1st order mass forces can be compensated by a balancer shaft which is the most common, the implementation of a reciprocating balancer weight would eliminate both but has certain drawbacks like complexity, friction and additional excitations. A 180° crank-pin offset does produce 1st order mass-moments and free 2nd order mass forces. In addition to that an uneven firing order gives drawbacks in orifice noise and excitations in other orders. The option of a 90° crank-pin offset in an inline 2-cylinder engine features a design, without free 2nd order mass forces on the one hand but small mass moments and an uneven firing distribution on the other hand. This paper investigates the difference on the NVH behavior between 360°, 270° and 180° inline 2-cylinder engines by the means of design and engine mount simulations and shows the comparative results of structural vibrations, airborne noise and orifice noise of these 2 versions having the same basic design and engine specifications measured on an acoustic chassis dynamometer.
Hubmann, Christian, Schoeffmann, Wolfgang, Friedl, Hubert, Graf, Bernhard
Liquid and Vapor Envelopes of Sprays from a Multi-Hole Fuel Injector Operating under Closely-Spaced Double-Injection Conditions2012-01-04624/16/2012
Liquid and vapor envelopes of sprays from a multi-hole fuel injector operating under closely-spaced double-injection conditions were investigated using a combination of high-speed schlieren and Mie scattering imaging. The effects of mass split ratio and dwell time between injections on liquid and vapor penetration have been investigated under engine-like pressures and temperatures. For the conditions evaluated, the results indicate that closely-spaced double-injection generally reduces liquid and vapor penetration.
Parrish, Scott E., Zhang, Gaoming, Zink, Ronald J.
Replicating Instantaneous Cylinder Mass Flow Rate with Parallel Continuously and Discretely Actuating Intake Plenum Valves2012-01-04174/16/2012
The focus of this paper is to discuss the modeling and control of intake plenum pressure on the Powertrain Control Research Laboratory's (PCRL) Single-Cylinder Engine (SCE) transient test system using a patented device known as the Intake Air Simulator (IAS), which dynamically controls the intake plenum pressure, and, subsequently, the instantaneous airflow into the cylinder. The IAS exists as just one of many devices that the PCRL uses to control the dynamic boundary conditions of its SCE transient test system to make it “think” and operate as though it were part of a Multi-Cylinder Engine (MCE) test system. The model described in this paper will be used to design a second generation of this device that utilizes both continuously and discretely actuating valves working in parallel. Throughout this paper it is possible to find a description of the operation and performance of the current IAS system, the goals for the second generation IAS system, and the means by which the authors are pursuing these goals. Iterations of the dynamic model will be described and results from these iterations will be shown and discussed. These results will then be used to shape the continuing research into the construction of the second generation IAS.
Gander, Aaron, Moskwa, John
Optical Analysis and Measurement of Crankcase Lubricant Oil Atomisation2012-01-08824/16/2012
Crankcase emissions are a complex mixture of combustion products and, specifically Particulate Matter (PM) from lubricant oil. Crankcase emissions contribute substantially to the particle mass and particle number (PN) emitted from an internal combustion engine. Environmental legislation demands that the combustion and crankcase emissions are either combined to give a total measurement or the crankcase gases are re-circulated back into the engine, both strategies require particle filtration. There is a lack of understanding regarding the physical processes that generate crankcase emissions of lubricant oil, specifically how the bulk lubricant oil is atomised into droplets. In this paper the crankcase of a motored compression ignition engine, has been optically accessed to visualise the lubricant oil distribution. The oil distribution was analysed in detail using high speed laser diagnostics, at engine speeds up to 2000 rpm and oil temperatures of 90°C. High resolution calibrated images show the passive behavior of lubricant oil once it has been supplied to critical engine components. The major mechanisms of oil atomisation have been identified and quantified from high speed images, the generation of oil droplets dp = 10 μm - 3 mm has been captured. The most significant generation mechanism was atomisation of oil films present on the surface of rotating components. The isolated contribution of the crank and camshafts to the atomised oil droplets present in the top of the engine has been recorded. Further breakup, evaporation and condensation from the surface of the atomised oil droplets will generate coarse and fine PM. Results from imaging data show good correlation with sub-micron PN sampling measurements captured in a previous study [1]; namely an increase in particle number concentration with increasing engine speed.
Johnson, Benjamin T., Hargrave, Graham K., Reid, Benjamin A., Page, Vivian J., wagstaff, Stuart
Modeling and Analysis of Powertrain NVH2012-01-08884/16/2012
Current modeling techniques of the powertrain noise, vibration and harshness (NVH) involve fully meshed structural components and rely, in general, on predefined excitation loads to evaluate linear transfer or structural attenuation functions. While effective for comparative assessment of various designs, these methods neglect the complex dynamic interactions between the powertrain structure and crankshaft, piston, valve train, timing drive, and accessory drive systems. This paper presents an overview of modeling methods of low and high frequency powertrain NVH with focus on dynamic interaction among structural components. A coupled and fully flexible multi-body dynamics model using AVL/Excite is presented. The model includes the cranktrain, crankcase, cylinder head, covers, oil pan, mounts, and transmission housing represented as finite element meshes. The main bearings are represented using elasto-hydrodynamic joints to account for the effect of oil film stiffness and damping as well as bearing clearance. The structural components are reduced using component mode synthesis and used to determine dynamic loads at various engine speeds and loading conditions. The main excitation sources relevant for both low and high frequency NVH and the influence of cylinder pressure, bottom end design, and crankshaft stiffness are discussed. An overview of piston related noise and modeling techniques to identify the causes and mechanisms leading to excessive impact noise in a floating piston pin design are presented.
Beloiu, Dumitru M.
Crankcase Sampling of PM from a Fired and Motored Compression Ignition Engine2011-24-02099/11/2011
Crankcase emissions are a complex mixture of combustion products and aerosol generated from lubrication oil. The crankcase emissions contribute substantially to the total particulate matter (PM) emitted from an engine. Environment legislation demands that either the combustion and crankcase emissions are combined to give a total measurement, or the crankcase gases are re-circulated back into the engine. There is a lack of understanding regarding the physical processes that generate crankcase aerosols, with a paucity of information on the size/mass concentrations of particles present in the crankcase. In this study the particulate matter crankcase emissions were measured from a fired and motored 4-cylinder compression ignition engine at a range of speeds and crankcase locations. A sequence of sampling equipment was used to characterize the emissions in the size range 5 nm - 19 μm; Cambustion DMS500 fast particulate spectrometer, TSI Scanning Mobility Particle Sizer (SMPS), TSITM Condensation Particle Counter (CPC) and, TSITM Aerodynamic Particle Sizer (APS). The combination of the two test engines and range of sampling equipment provided new information on the generation and behavior of aerodynamic particulate matter within an engine crankcase. Data is presented for the effect of controlled parameter changes on number distributions over the measured particle size range. A complex lognormal bimodal size distribution of sub micron accumulation mode particles was present in the crankcase of both engines at a low idle speed of 900 rpm. At 1400 rpm this complex distribution was not present. Increasing the engine load, on the fired engine, initially reduced the particle number concentration with a final significant increase in particle number concentration at 75% load. At 900 rpm 50% load there was a single strong peak at 32 nm in the rocker cover however sampling from the push rod gallery and sump showed a strongly bimodal distribution with peaks at 32 nm and 133 nm. All other sampling data, from the fired engine, was consistent at each sampling location. The SMPS results, 15-665 nm, on the motored engine showed location dependency, with the highest number concentration of particles present in the push rod gallery.
Johnson, Benjamin T., Hargrave, Graham K., Reid, Benjamin, Page, Vivian J.
Design and Development of 3- Cylinder: 75 kW/liter, High Power Density Diesel Engine for Passenger Car Application to Meet Euro IV/V Emission Norms2011-26-00331/19/2011
To meet the latest trends in internal combustion engines pertaining efficiency, emissions and durability, downsizing of the engine has become the key focus area. This paper describes about a robust, reliable and an integrated approach used in design and development of state of art high power density/ high speed engine developed from the concept, which can be adopted for passenger car and LCV application. A three-cylinder, 1.5 liter displacement diesel engine, fully balanced is being designed with an objective to produce 115kW @ 4200 rpm, delivering a specific power output over 75 kW/liter, which is at par with a contemporary class of specification in it. In the first stage, a derated version of 75 kW (50 kW/liter) with Euro-IV and Euro-V specifications is targeted aiming at smaller car and light motor vehicle segment and a prime-mover for hybrid application. This paper outlines various technologies applied in developing this engine to achieve high power density, low exhaust emissions, and low noise and vibration characteristics. Major thrust has given on mechanical design and manufacturing aspects and have been discussed in this paper.
Ramdasi, S. S., Mulay, S. K., Chitnis, P. P., Walke, N. H., Babu, K. Ganesh, Patwardhan, M. A., Dhande, N. B., Marathe, N. V.
The New Rotax ACE 600 Engine for Ski-Doo2010-32-00019/28/2010
Customers are demanding propulsion systems giving as much as possible riding pleasure while still considering strict environmental regulations. BRP-Powertrain developed an engine for their snowmobile brand Ski-Doo fulfilling both needs. The Inline two cylinder four stroke engine using a multi port fuel injection system significantly contributes to an impressive and up to now second-to-none cruising range of 29 miles per gallon. With 42 kW at 7250 1/min the performance target was achieved. Excellent combustion stability allows Lambda values of 1.1 and higher in part load. This also contributes to the good fuel efficiency. The geometrical layout of the engine was driven by vehicle boundaries. All the power pack components had to be installed using a minimum of space. A low center of gravity was an absolute need for stable riding properties of the snowmobile. Therefore the crankshaft was put as low as possible which left no room for an oil pan underneath the engine. This led to a dry sump oil circuit evacuating the crank chamber by a pump to an integrated oil tank. The rear engine contour is forming one wall of the tank, which is a unique feature. This detail shows the high grade of integration of components. The perfect cooperation of both frame designers and engine developers was supported by using a digital mock up at each stage of the development process. Additional customer value is given by the possibility to start the engine down to minus 40 degree Celsius, maintenance free valve tappets and a nearly negligible oil consumption which was achieved by an optimized cylinder honing process.
Gumpesberger, Michael, Gruber, Stefan, Simmer, Michael, Sulek, Christian, Stiebinger, Christian, Burgstaller, Josef
Valve Cover's Numerical Vibro-Acoustic Analysis And Experimetal Correlation2010-01-14166/9/2010
This work describes a numerical vibro-acoustic analysis of a gasoline engine's cylinder head of recent development. The analysis was divided in two main steps: definition and correlation of the numerical model by mean of comparison with tests data, and development of a methodology to identify the potentially critical modes for the NVH performance without knowing the real operational boundaries of the sub-system. The vibrational analysis has focused on the definition of a finite element model for reproducing the behaviour of the component, experimentally obtained by accelerometers placed on the top of the cover. The subsequent acoustic analysis has been executed through a boundary element model. The comparison between numerical results and experimental data was very good. Once the models have been validated and vibration and acoustic transmissibility indexes have been defined, system's critical modes have been identified, disregarding the real forces that arise during engine working conditions; this allows a faster component optimization and, consequently, a reduction of the whole engine system development time, improving it from a NVH point of view. Such methodology had been further validated and developed and is now part of the standard validation plan for new engines.
Armentani, Enrico, De Stefanis, D., Esposito, R., Martorelli, M., Parente, A.
OPTIMIZATION OF THE WALL THICKNESS OF A PLASTIC VALVE COVER2009-36-007010/6/2009
Recent advances in hardware and software have allowed to development teams to use their time not only solving common CAE analyses but also thinking about the development of CAE optimization environments. Optimization comes like a tool capable to drive design parameters towards regions where selected characteristics of the project can be further improved. This work presents one case that serves to illustrate the application of a optimization technique well known as multi-objective optimization. In the example a Multi-Objective Genetic Algorithm is used to define the thicknesses of several regions over a valve cover looking not only for lower flexibility but also to lower mass. In this case, the commercial code PERMAS was used to verify the structural behavior of the valve cover, as well as to calculate its mass. Design variables were restricted to geometry parameters - cover thickness - while optimization objectives comprised reduction of mass besides of maximization of the cover stiffness aiming to reduce cover leakage. The commercial code modeFRONTIER was used as the process integrator and optimization tool.
Trindade, Wagner Roberto da Silva
Plastics expand their rangeOFHJUN09_036/1/2009
From high-speed train exterior panels to powertrain components, plastics and composite materials are finding their way into more off-highway applications. The motivation for using composites is strong even as such motivations vary between applications. In one application, reducing mass for better fuel economy is important. Another application may stress reducing part and warranty costs. Understanding the breadth and depth of composite manufacturing processes as well as the variety of materials themselves can be daunting. The alphabet soup of manufacturing processes (RTM, VARTM, SCRIMP, etc.) is matched by the names of polymers (PEEK, PET, PAI, etc.). Broadly speaking, there are plastics that can be heated and reformed called thermoplastics, and plastics that are polymerized into solids called thermosets.
Morey, Bruce
The Development of High Efficiency Crankcase Ventilation and Oil Mist Separator for a Heavy-Duty Diesel Application2008-01-268710/7/2008
Both current exhaust emission legislations and continuously growing customer demand of less oil consumption drive the diesel engine manufacturers to develop more efficient crankcase ventilation and oil mist separation systems. In recent years, integrated design concepts are also considered for almost all sub-systems to achieve compact solutions fulfilling the tightened packaging requirements and more challenging cost targets. This paper presents crankcase ventilation and oil mist separator unit of new generation Ford Otosan Ecotorq Heavy Duty Diesel engines and all work to reach its final configuration, the three-layer filter element with an integrated impactor design. The unit has a compact design as it is integrated to engine valve cover. Challenges brought by the packaging boundary conditions in draining the collected oil by high efficient media are overcome through the extensive experimental development work, which includes tests on special rigs, engines run on dynamometers and fleet tests. Effects of different media types, deflector and impactor designs, oil repellent chemicals and pre-filters are discussed based on the test results.
Gokten, Murat, Kurnaz, Goktan, Ergen, Omer Rustu, Copley, Daniel
Columbus ECLS Activation and Initial Operations2008-01-21356/29/2008
European Space Agency's (ESA's) Columbus module was launched on February 7, 2008. This marks the completion of more than 10 years of development. It is a major step forward for Europe in the area of Environmental Control and Life Support (ECLS) as Columbus contains several major assemblies which have been developed in Europe. These include the Condensing Heat Exchanger, Condensate Water Separator and the Cabin Fans. The paper gives a short overview of the system and its features and it will report the experiences from the initial activation and operations phase.
Witt, Johannes, Hinderer, Stephan, Bockstahler, Klaus, Müller, Roland, Szigetvari, Zoltan
Global Growth of Diesel Engines and PM Usage2008-01-11114/14/2008
Diesel engines are trying to make inroads in North America and growing at a steady pace globally. This article describes briefly the diesel engine and their components. Market growth is identified and a number of parts that are suitable for powder metal is indicated.
Narasimhan, Kalathur S., Boreczky, Eric
A New Cylinder Deactivation by FEV and Mahle2008-01-13544/14/2008
Rebbert, Martin, Kreusen, Gerhard, Lauer, Sven
Noise Source Identification of a Diesel Engine Using Inverse Boundary Element Method2008-01-07294/14/2008
The inverse boundary element method (IBEM) is presented to accurately identify the noise sources of a diesel engine in this study. The sound pressures on four near-field planes were measured as inputs for the method. Then, the acoustic model of the full diesel engine was established using the boundary element method, and the acoustic transfer vectors (ATV) between the surface normal velocity and acoustic pressure at field points were calculated over the frequency range of interest. Based on the measured sound pressure and the ATVs, the surface normal velocity distribution of the diesel engine was reconstructed by the IBEM. The reconstructed pressures at two reference field points were compared with the measured ones. Furthermore, the panel contribution of each engine component was analyzed through the reconstructed surface velocity. The results show that the IBEM method is well suited for the noise source identification of a diesel engine because it accurately reconstructs the surface normal velocity using only a low number of sound pressure measurement points.
Shu, Ge-qun, Chen, Da-liang
Effects of Seal Viscoelastic Properties on Engine Exterior Cover Noise and Vibration2007-01-22855/15/2007
Engine exterior cover seals are typically made of elastomeric materials and used to seal the interfaces. The design of engine/transmission seals has been traditionally considered from the sealibility aspects. Recently, there have been additional demands that these seals be designed to reduce the vibration transmitted from engine/transmission and to attenuate the radiated noise. To accomplish this goal, the frequency-dependent viscoelastic properties of the seals will have to be considered. This article examines the frequency-dependent viscoelastic properties of some common elastomeric seals. The impacts of these materials on an engine valve cover noise and vibration are particularly investigated. Some design strategies are also discussed to optimize the viscoelastic effects of the elastomeric seals.
Lu, Y. Charles
Assembled Camshaft with Integrated Oil Mist Separation2007-01-02604/16/2007
The worldwide focus on reducing the emissions, fuel and lubricant consumption in engines is leading engineers to consider the crankcase ventilation and oil mist separation system as an important means of control. In today's passenger cars the oil mist separation systems mainly use the inertia effect (e.g. labyrinth, cyclone etc.). In this work a new concept for oil mist separation will be presented. The concept combines the assembled camshaft with an oil mist separator. This allows for a pre-separation effect through centrifugal forces at the entry point to the rotating camshaft and an additional efficiency gain thru the swirl generator, which is integrated into the camshaft.
Schellhase, Torsten, Sauter, Hartmut, Ruppel, Stefan
CAE approach for Plastic Valve Cover System- Part 22006-01-08274/3/2006
The Plastic Valve Cover System (PVCS) should provides a leak proof seal to the cylinder head under engine temperature, isolate the vibrations transmitted from the engine through the cover to the environment, control the crankcase pressure and house the device to separate oil from the blow-by gas. In order to increase the stiffness of PVCS, short glass fibers and minerals are added during the injection molding of the plastic valve cover. The presence of the fibers results in a component with highly anisotropic thermo-mechanical properties that was not accounted in the previously approach [1]. This paper describes the updated CAE approach with the incorporation of the short fiber anisotropy into the design of cylinder head valve covers.
Pereira, Dimitrius C., Schnurrenberger, Joachim, Lu, Y. Charles, Bastías, Pedro, Anderson, Mike, Nation, Keith
High Performance Polyamides in Demanding Automotive Thermal Management Applications2005-01-409611/22/2005
High Performance Polyamides (HPPA) represent a fast growing family of polymers, with broad applicability in demanding applications where traditional materials such as nylon 66 are not suitable. This paper reviews the basic chemistry of the nylon product family, demonstrates how the HPPA family differs from standard nylon with a focus on semi-aromatic nylons known as polyphthalamides (PPA). We will demonstrate how PPA is an excellent candidate for thermal management applications where traditional polyamides are not suitable via specific performance data measured at the lab scale, along with commercial applications that provide validation of HPPA use.
Glasscock, David, Tangary Atolino, Walter Jose, Kozielski, Gary, Martens, Marvin
Finite Element Analysis for a Plastic Valve Cover System with anisotropic thermo-mechanical properties2005-01-401911/22/2005
In order to increase the stiffness of cylinder head plastic valve cover system (PVCS), short glass fibers and minerals are added during the injection molding of the plastic valve cover. The fibers orient themselves according to the local characteristics of the flow and the geometry of the part. The presence of the fibers results in a component with highly anisotropic thermo-mechanical properties. Traditional finite element analysis methods do not account for this, very important, phenomenon. The present manuscript describes work conducted at Dana Corp. aimed at incorporating short fiber anisotropy into the design of cylinder head valve covers.
Pereira, Dimitrius Caloghero, Bastías, Pedro, Anderson, Mike, Schnurrenberger, Joachim, Felippe, Bruno
Sludge Formation in OTTO Cycle Engines2005-01-21735/11/2005
A review of the specialized literature was carried out to study the process of sludge formation and to understand the reasons for the increasing occurrences of these deposits in Brazil. The following items of consensus were reached: sludge precursors arise from the partial oxidation of fuels; fuel composition has a direct influence on sludge formation; blow-by is the main contact between fuel derived products and the oil. Based on this information and on the accumulated experience in investigating occurrences of sludge, a test methodology was developed for evaluating the sludge formation characteristics of lubricating oils.
Lastres, Luiz Fernando Martins, de Souza Rocha, José Roberto, de Almeida, Marco Antônio Gonzalez, Benvenutti, Leandro H.
Effect of HPDC Parameters on the Performance of Creep Resistant Alloys MRI153M and MRI230D2005-01-03344/11/2005
The growing demand for the use of magnesium alloys in the production of automotive powertrain components led to the development of creep resistant diecasting alloys MRI153M and MRI230D. The present paper addresses the main high-pressure die casting parameters, which significantly affect the performance of components, produced of these new alloys. A systematic study was carried out in order to correlate die-casting parameters to the performance of new alloys. The results obtained clearly indicated that optimization of molten metal and die temperatures, injection profile parameters and lubrication mixtures allowed to improve the die castability and service properties of the new alloys and produce high performance components with intricate geometry. This was manifested by production of several practical demonstrators such as gearboxes, oil pans, oil pumps and crankcases.
Gertsberg, G., Nagar, N., Lautzker, M., Bronfin, B., Moscovitch, N., Schumann, S.
Spatial Transmissibility of Plastic Cylinder-Head Covers2005-01-15154/11/2005
The transmissibility technique has been traditionally used for evaluating the NVH performance of isolated, rigid structures such as the elastomer mount isolated automobile engine. The transmissibility quantity provides information on how a structure reduces vibration as subjected to dynamic loading and thereby attenuates noise. In the present study, the transmissibility is applied to a non-rigid, plastic structure - the engine cylinder-head cover module. The cover module includes primarily a thin, plate-like cover and the elastomer isolation system. At low frequencies, the cover will behave as a rigid mass and thus display a major peak at its resonant frequency. At high frequencies, the cover will vibrate as a flexible panel and thus display multiple peaks with magnitudes differing from point to point across the cover surface. As a result, the transmissibility calculated would have a spatial resolution, called the spatial transmissibility. Comparing to the traditional methods of quantification the spatial transmissibility is a more effective method in evaluating the NVH performance of the cover system, especially in the early design stage. A comprehensive study of spatial transmissibility is conducted on a production plastic cylinder-head cover module. The experiments are conducted on a full vehicle equipped with these covers. The tests are run at various driving conditions and the accelerations at the cover fastening bolts and cover surface are measured. The transmissibilities are calculated based on the acceleration data. The results show that the transmissibilities at varying driving conditions fall into the similar pattern of curves, indicating that it is an independent property of the cover system.
Lu, Y. Charles, Periyathamby, Haran, Krishna, Murali M. R., Nash, David A.
Ecotec 2.4L VVT: A Variant of GM's Global 4-Cylinder Engine2005-01-19414/11/2005
General Motors adds a larger displacement more powerful variant to its global 4-cylinder engine family. The new Ecotec 2.4L VVT, being introduced in the 2006 Pontiac Solstice is the latest variant within the Ecotec engine family. This new engine is built on the heritage and excellent reputation of the Ecotec 2.2L(1), the global 4-cylinder engine introduced for the North American market in the 2000 model year Saturn L-series. Ecotec engines are now offered in many additional GM platforms in North America as well as in Europe. The Ecotec 2.4L VVT shares many parts with the Ecotec 2.2L(1), with addition of cam phaser technology to enable variable valve timing (VVT) along with several structural enhancements. The Ecotec 2.4L VVT produces 25% more power, impressive torque at lower engine speeds and offers a number of other advantages. Production of the Ecotec 2.4L VVT is integrated with the Ecotec 2.2L(1) resulting in efficient use of the manufacturing systems already in place, at the same time providing flexibility to split the production volumes for the two engines based on the demand.
Dugdale, Peter H., Rademacher, Roger J., Price, Bruce R., Subhedar, Jay W., Duguay, Roger L.
The Development of the New Ford Heavy Duty Truck Engine, ECOTORQ2004-01-268810/26/2004
FORD OTOSAN has developed a new heavy-duty diesel engine, ECOTORQ, for the new Ford Cargo Trucks whose production started in September 2003. The engine is 7.3 liters, 6-cylinder in-line, with common rail fuel injection system and overhead camshaft design having 4 valves per cylinder. The engine meets the Euro-III exhaust emissions limits, which were in effect when it was introduced, and the engine incorporates the potential to meet Euro-IV. Modern computation and simulation methods were used and extensive experimental studies were made during the design and development stages, which helped reach the targets of compactness, modular structure, low fuel consumption, low noise level and low emissions.
San, Dogan, Guraslan, Ergun, Ergen, Omer Rustu, Kanar, Korhan
Possibilities of Ultra Low Viscosity Fuel Saving Gasoline Engine Oil2004-01-19366/8/2004
Improvements in motor oil fuel efficiency have been mainly achieved through lower viscosity and usage of friction modifiers. Further reduction in viscosity to below SAE #20 could be useful for improvement of fuel efficiency. JASO gasoline engine tests were conducted with an ultra low viscosity oil containing mineral base stocks that showed minimum drive torque during an engine motoring test. The results showed an increase in viscosity, increase in oil consumption and deterioration of detergency. In order to solve these problems, an ultra low viscosity engine oil formulated by a special synthetic base stock with improved volatility was developed. The results of a High Temperature Oxidation Test showed this synthetic oil to have better performance than the mineral oil.
Tamoto, Yoshitaka, Kido, Masahiko, Murata, Hideyuki
Long Drain/Fuel Efficient Engine Oils Based on the ZDTP Substitute Additive Technologhy2003-01-20035/19/2003
Zinc dialkylphosphate (ZP), a sulfur free analogue of Zinc dialkyldithiophosphate (ZDTP) has been synthesized and tested for engine oil application. The sulfur free engine oil based on ZP showed excellent TBN retention and engine cleanliness in several engine tests which were operated at low and high temperatures. A prototype low phosphorus (0.05%) and low sulfated ash (0.5%) engine oil exhibited even better longer drain performance than a fully synthetic engine oil containing 0.1% P and 1.1% sulfated ash. Thus, zinc dialkylphosphate can be a promising candidate as a ZDTP substitute for future catalyst system compatible engine oil.
Yagishita, Kazuhiro, Igarashi, Jinichi
Turbocharging the Chrysler 2.4L Engine2003-01-04103/3/2003
A turbocharged version of the 2.4L engine has been developed by the Chrysler Group of DaimlerChrysler Corporation. This new engine is derived from the proven 2.4L 4-cylinder, with significant changes to achieve a durable, high performance package for the PT Cruiser vehicle. The package includes an integrated turbocharger / exhaust manifold, oil squirters for piston cooling, and numerous other upgrades to satisfy the demanding performance, emissions, and durability requirements unique to this powertrain. The purpose of this paper is to describe the mechanical changes to the base engine, the unique turbocharger configuration, and the new parts necessary to accommodate the higher output.
McKissick, Garry W., Schmidt, David M.
A Comparative Study of New Magnesium Alloys Developed for Elevated Temperature Applications in Automotive Industry2003-01-01913/3/2003
Recently several new magnesium alloys for high temperature applications have been developed with the aim to obtain an optimal combination of die castability, creep resistance, mechanical properties, corrosion performance and affordable cost. Unfortunately, it is very difficult to achieve an adequate combination of properties and in fact, most of the new alloys can only partially meet the required performance and cost. This paper aims at evaluating the current status of the newly developed alloys for powertrain applications. The paper also addresses the complexity of magnesium alloy development and illustrates the effect of alloying elements on properties and cost. In addition, the paper presents an attempt to set the position of each alloy in the integrated space of combined properties and cost
Aghion, E., Bronfin, B., Von Buch, F., Schumann, S., Friedrich, H.
Putting the Stock Back in Stock Car Racing: Developing the GM LS1 V8 for Short-Track Competition2002-01-335612/2/2002
This paper details the joint effort of GM Racing and the American Speed Association (ASA) to introduce a production V8 engine into the ASA stock car racing series. With only minor changes, the selected engine was able to replace the purpose-built V6 racing engines that had been used previously in the series. The objectives of this program were to reduce the cost of racing for competitors and to demonstrate that advancements in design, materials, electronics and manufacturing have made a low-cost production engine a viable alternative to an expensive, purpose-built racing engine.
Engel, Dan, McPhail, Mark, Taylor, Don
New Modified Dow Polyamide Resins Solving Under-the-Hood Warpage Problems2002-01-21047/9/2002
Polyamide resins are well established within the automotive industry and are widely used in a range of demanding under-the-hood applications such as valve covers and air intake manifolds. In reality however, the disadvantages of conventional nylon products, such as excessive warpage and poor dimensional stability to name but two, make it increasingly difficult for engineers to produce the ever more complex parts demanded by new engine developments. In this paper we shall introduce a new range of modified Dow Polyamide resins that greatly reduce the above mentioned disadvantages. In comparisons with commercially available nylon 6 and 66 materials we shall illustrate improved warpage behaviour and lower moisture pick-up in combination with excellent chemical resistance to, for example, hot motor oil and ethylene glycol. In summation, examples will be provided to illustrate the improved utility of these new, modified Dow Polyamide resins.
Shields, Nigel, Sabat, Philippe J.
On the Use of Spatial Transmissibility to Evaluate the NVH Performance of Engine Cover Assembly2002-01-04583/4/2002
In the present study, the NVH performance of an engine valve cover assembly is analyzed by the use of “spatial transmissibility (TR)”. It is a measure of the spatial response of the cover relative to the spatial response of the underlying structure to which it is connected. A prototyped engine valve cover assembly is examined. The cover transmissibility is computed through the finite element method and also measured by experimental testing. Various isolation systems have been examined and different cover materials have been investigated, including magnesium and thermosetting plastic. The transmissibility provides a strategy for evaluating the NVH characteristic of engine cover assembly in a much more timely, cost-effective manner, while the product is still in the early conceptual stage.
Lu, Y. Charles, Anderson, Michael E.
Coolant Flow Control Strategies for Automotive Thermal Management Systems2002-01-07133/4/2002
The automotive thermal management system is responsible for maintaining engine and passenger compartment temperatures, which promote normal combustion events and passenger comfort. This system traditionally circulates a water ethylene glycol mixture through the engine block using a belt-driven water pump, wax pellet thermostat valve, radiator with electric fan, and heater core. Although vehicle cooling system performance has been reliable and acceptable for many decades, advances in mechatronics have permitted upgrades to powertrain and chassis components. In a similar spirit, the introduction of a variable speed electric water pump and servo-motor thermostat valve allows ECU-based thermal control. This paper examines the integration of an electric water pump and intelligent thermostat valve to satisfy the engine's basic cooling requirements, minimize combustion chamber fluctuations due to engine speed changes, and permit quick heating of a cold block. A controller architecture is introduced to regulate the operation of these two components. A series of mathematical models are presented to describe the dc servo-motor actuated thermostat valve, electric water pump, and thermal behavior of in-cylinder engine components. The multiple node resistor-capacitor engine model estimates the thermal behavior of the cylinder wall and cylinder head for use in the model-based control algorithm. Representative results are presented and discussed to investigate the performance of the proposed control strategy in regulating the thermal management system for various operating speeds.
Wagner, John R., Ghone, Mrudula C., Dawson, Darren W., Marotta, Egidio E.
Engine Internal Dynamic Force Identification and the Combination with Engine Structural and Vibro-Acoustic Transfer Information2001-01-15964/30/2001
The vibration-generating mechanisms inside an engine are highly non-linear (combustion, valve operation, hydraulic bearing behavior, etc.). However, the engine structure, under the influence of these vibration-generating mechanisms, responds in a highly linear way. For the development and optimization of the engine structure for noise and vibration it is beneficial to use fast and ‘simple’ linear models, like linear FE-models, measured modal models or measured FRF-models. All these models allow a qualitative assessment of variants without excitation information. But, for true optimization, internal excitation spectra are needed in order to avoid that effort is spent to optimize non-critical system properties. Unfortunately, these internal excitation spectra are difficult to measure. Direct measurement of combustion pressure is still feasible, but crank-bearing forces, piston guidance forces etc. can only be identified indirectly. Inverse identification of the main internal excitations through operational acceleration measurements, combined with laboratory tests of FRF matrices, is the only possibility. This paper discusses inverse engine internal force identification using operational accelerations and laboratory FRF-matrices and the use of engine FRF matrices to assess modifications and variants with and without this excitation information.
Van Herbruggen, J., van der Linden, P. J. G., Knittel, H.-J., Schnur, J.
Electronic Throttle Control With Contactless Position Sensor And Smart Power Full-Bridge2001-01-09843/5/2001
Electronic throttle systems are becoming more and more important in today's motor vehicles. These systems consist of: a throttle valve with an electrical actuator and a transmission a position feedback an electronic acceleration pedal an electronic control unit (ECU) a semiconductor h-bridge for driving the motor. The electronic acceleration pedal gives a set point to the ECU. A control signal is generated and moves the motor of the throttle valve with a semiconductor h-bridge to the requested position. The voltage drop of a potentiometer is used here as control feedback signal. The potentiometer in the throttle valve is moved very often and has a rough environment like high temperature and vibrations. Therefore this system has a lot of problems with mechanical attrition and reliability during the whole system lifetime. The accuracy of the position control decreases over time. To avoid mechanical wear and tear, Infineon Technologies has developed a new concept for measuring the throttle position, based on a contactless sensor. The GMR-C6 is a giant magneto-resistive sensor which detects changes in the direction of a magnetic field. The present SAE paper will describe the construction of the sensor, the signal conditioning and the software algorithms. Moreover, a semiconductor h-bridge which has been specially developed for electronic throttle control will also be introduced. A complex logic circuit in the smart power device allows a very extensive diagnosis which is necessary to fulfill OBDII. Our vision for the future is a mechatronic solution for the throttle. That means all components are integrated into the throttle package. The control of the position is done internally. Only 4 wires are left: 2 for supply and 2 for communication.
Pechlaner, Andreas, Steurich, Björn
Engine Lubrication System Model for Sump Oil Temperature Prediction2001-01-10733/5/2001
A flow and heat transfer model of an engine lubrication system has been developed in order to predict sump oil temperature and study heat transfer mechanisms within the lubricating oil circuit. The objective was to develop the capability of simulating all the energy transfers between the oil and the combustion process, the engine coolant, and the engine bay air. The model developed in this study simulates a V8 spark ignited engine. Included in this simulation is a bearing model for friction heat generation, a combustion heat input model, and component models for each key heat transfer site in the lubricating oil circuit. The model predicts sump oil temperatures under different engine operating conditions and simulation results were compared to test data with good agreement. The sensitivity of oil temperature to engine speed, engine load, coolant temperature, piston friction, bearing heat energy generation, piston design, water jacket depth, and oil flow rate(s) was studied. The assumptions made during modeling are discussed along with an estimate of their significance. Further, all of the significant heat transfer mechanisms in the oil circuit are discussed. This study shows that a lubricating oil circuit model is a useful tool for engine concept design, as well as providing an understanding of the mechanisms that effect sump oil temperatures.
Zoz, Steve, Strepek, Steve, Wiseman, Marc, Qian, Cheng
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