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Volvo Eicher Comm Veh Ltd 16, 17, 18th Nov 2011
Pithampur LATEST TRENDS IN DESIGN & DEVELOPMENT OF I.C.ENGINES
Piston Engines
Piston machines are machines in which energy is
transferred from a fluid ( a gas or liquid) to a moving
displacer ( e.g. a piston ) or from piston to the fluid.
Periodically changing working chamber because of motion
of piston is the characteristic of the Piston Engine.
Combustion Process
Fuel
Working cycle
Mixture formation
Gas exchange control system
Charging system
Configuration / Design
Ignition system
Cooling system
Load adjustment / control system
Speed range
Application / Purpose
Classification of I.C. Engines
Combustion Process
Otto cycle, diesel cycle, Combined cycle
Fuel
Liquid fuels
gasoline, kerosene, ethanol, LNG, LPG, etc
Diesel, bio-diesel, heavy fuel oils, etc
Gaseous fuels
Methane (CH4), CNG, Hydrogen, etc
Hybrid fuels
Gasoline + Ethanol, Diesel + ethanol, Diesel + bio-diesel,
Diesel + CNG, CNG + Hydrogen, etc
Working cycle
2-stroke, 4-stroke
Classification of I.C. Engines
Mixture formation
External Mixture, Internal Mixture
- Homogeneous mixture, heterogeneous mixture
- Manifold injection, Indirect injection, Direct injection
Gas exchange control system
through slots or ports
through poppet valve
through slide valve
Configuration / Design
Inline, V, W, Boxer (horizontal opposed), X, radial
Single cylinder, multi-cylinder
Charging system
Natural aspiration
Supercharging
- Mechanical supercharging, exhaust turbo-charging
Classification of I.C. Engines
Ignition system
Supplied ignition (spark ignition)
Auto ignition (Compression ignition)
Cooling system
Direct cooling ( air cooling ) with and without fan
Indirect cooling ( liquid cooling )
Load adjustment / control system
Quantity control ( constant air-fuel mixture ratio)
quantity of mixture controlled
Quality control ( variable air-fuel mixture ratio )
quantity of fuel OR quality of mixture ratio controlled
Classification of I.C. Engines
Speed range
Low speed : upto 200 rpm for diesel engines
Medium speed : from 200 to 1000 rpm for large diesel engines
1000 4000 rpm for normal diesel engines
< 4000 rpm for gasoline engines
High speed : > 4000 rpm for gasoline & diesel engines
Sports & Racing : > 10000 rpm
Application / Purpose
Land based vehicles road vehicles, off-road vehicles, rail
Agricultural machines & vehicles harvesting m/c, tractors
Industrial
Stationary
Marine
Aircraft
Internal Combustion Engines
Specific Power
Torque curve
Speed range
Fuel economy efficiency
Power takeoff
Weight / space
Exhaust Emissions
Noise
Functional Requirements of I. C. Engines
Reliability
Durability
Serviceability
Flexibility
Recycling
Cost initial, operating
Design upgradability
Others
On-Road Engines : Application areas
Passenger Transport
2-wheeler
3-wheeler
4W Passenger car
4W Utility vehicles
4W SUV
4W Mini Buses : School bus
4W Heavy duty Buses
Goods Transport
3-wheeler
4W LMV
4W LCV
4W MCV
4W HCV
Multi wheeled, multi-axle Tractor Trailers
Off-Road Engines : Application areas
Construction
Residential complexes
Commercial complexes
Roads and highways
Railways
Tunnel
Runways
Educational institutes
Industrial
Mining
Agriculture
Power generation
Pleasure
Special Purpose Vehicle
Defense
Specific demands of off-road engines
Specific power
PERFORMANCE Specific torque
Torque back-up
Low end torque
Speed range
Load response
OPERATING
Noise
REQUIREMENTS
Vibration
GOVERNING Fuel economy
ACCESSORIES Lub oil consumption
Inclined operation
COOLING
High altitude
PACKAGING operation
Why diesel !!!
Tier 4 Tier 4
US EPA Tier 1 Tier 2 Tier 3
Interim Final
Chamber geometry
Charge density + Motion
Engine Design Strategies Advanced Control on Injection strategy
Combustion optimization Advance swirl-assisted combustion systems
Cooled Exhaust Gas Recirculation (EGR)
Boosting : Variable Geometry Turbocharging (VGT)
High Pressure Common Rail (HPCR) fuel systems
Electronic controls
Crankcase filtration
After-treatment Strategies
Diesel Oxidation Catalyst (DOC)
Catalyzed Diesel Particulate Filter (DPF)
Selective Catalytic Reduction (SCR)
NOx adsorbers
Engine development considerations
Route 01 :
The other scenario is to use combustion optimization and
cooled EGR for NOx reduction along with a catalyzed Diesel
Particulate Filter (DPF) for PM control.
Route 02 :
Use of SCR after-treatment for NOx reduction and in-
cylinder combustion for PM control together with some
particulate after-treatment.
Global scenario :
> 56 upto 250 kW
Indian Scenario :
Class A : upto 30 kW
Class B : > 30 upto 60 kW
Class C : Emerging market >60 upto 130 kW
Engine Design Process
Vc = Clearance Volume
Vd = Displacement or Swept Volume
Vt = Total Volume
TC or TDC =
Top or Top Dead Center Position
BC or BDC =
Bottom or Bottom Dead Center
Position
Compression Ratio (CR)
Vd Vc
CR
Vc
Engine Characteristics
Volumes, cc
Different Volumes considered for Compression Ratio calculation
Stroke Volume (Vs)
Volume between valve head and cylinder head bottom faces (V9)
Dead volume, Vd
Stroke (L)
m/sec Mean piston speed
= 2 L N / 60
2-st diesel 200 rpm 8
BDC
4-st large
diesel
1200 rpm 10
4-st Truck
diesel
2200 rpm 13
Influencing
4-st Light
Truck diesel
4000 rpm 14 parameters
25
diesel
Power
Specific
kW / Litre
Medium speed
12
20
diesel NA
High speed
12
18
diesel NA
5
Truck diesel TCIC
30
> 36
5
45
diesel TCIC
Advanced high
3
speed car
65
> 80
diesel TCIC
2 gasoline NA
Racing
0.5
> 120 200
kg/ kW
Weight
Specific
Engine Characteristics
Engine Characteristics
Mean Effective Pressure Gas work
Gas work is the work done by the cylinder pressure at the piston.
Indicated mean pressure (imep) is the specific
work acting on the piston area
imep = p. dV
p
Brake Mean Effective Pressure (bmep) is the average +
gas pressure usefully acting on the piston area
over one cycle -
bmep = 2 T / Ve . K
+ - pdV -
imep
Friction Mean Effective Pressure (FMEP) is difference pdV
between imp and bmep. FMEP is the power loss due to
mechanical friction in the engine and the pump Ve
losses in the crankcase.
fmep = imep - bmep
Engine Characteristics
BMEP (bar) T = bmep. A. L / 2 N
20 Medium duty / off-road TCI diesel Power of an engine is dependent on its
size and speed. Therefore, it is not
16 Racing engines possible to compare engines on the basis
of power or torque
13 Gasoline NA car engines A larger size engine will produce more
torque for same bmep.
6-17%
24-31%
9-17%
10-13%
Friction improvement potential
FC improvement
10 envelop
0 10 20 30 40
DOWNSIZING (%)
Development Trend of diesel engine Specific power
100
90
Max Gas Pressure
Specific Power (kW/L)
ARAI Target
60 PASS CAR / HIGH SPEED Diesel 75 kW/L
40
40
IDI kW/L
TRUCK / HD Diesel
20
Max Gas Pressure
DI 70 100 bar
1920
1940
1960
1980
2000
2020
Year
Trend of Specific weight for diesel engines
6
rated speeds
5 ( < 3000 rpm)
Weight / power ( kg/ kW )
rated speeds
1 ( > 3000 rpm)
%
%
%
50
30
20
%
43
BRAKE POWER
GAS EXCHANGE
2.5%
Current Status
1.5% FRICTION
43%
Thermal
Efficiency
ACCESSORIES
3%
58
20
22
%
53
BRAKE POWER
GAS EXCHANGE
2%
Future Targets
FRICTION
1%
53%
Thermal
Efficiency
2%
ACCESSORIES
Thermal Efficiency Trends