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SAE International

Diesel Engine Technology Engineering Academy     

Open
Enrollment

I.D.# ACAD03Printable Description
Duration: 5 Days
Upcoming open enrollment dates being scheduled. Please check back.

Hotel & Travel Information

SAE International, in a continuing effort to provide options and convenience for professional development and training opportunities, is pleased to offer the 2009 Diesel Engine Technology Engineering Academy at Southwest Research Institute (SwRI) in San Antonio, TX.

This Academy covers the diesel engine engineering principles and practices necessary to effectively understand a modern diesel engine. Types of engines addressed include naturally aspirated, turbocharged, pre-chamber, open chamber, light duty, and heavy duty. It is an intensive learning experience comprised of lecture and structured practical sessions, including a team-solved case study problem. Evening sessions are included.

Attendees will receive a copy of the textbook, Diesel Emissions and Their Control, by lead instructor Magdi K. Khair and W. Addy Majewski.

Practical Component

This Academy includes several practical activities, including a team-solved case study.

The SwRI technical tour will include the Petroleum Products Research Department and the Emissions Research and Development test labs.The Petroleum Products Research Department measures the quality and determines regulatory compliance of fuels, automatic transmission fluids, brake fluids, gear lubricants, hydraulic oils, coolant, antifreeze, gasoline and diesel crankcase oils. The Emissions R&D performs development and durability testing for the locomotive, marine, power generation, and gas transmission industries. The group specializes in performing programs that address emissions reduction, efficiency enhancement, and improved durability and reliability.

About Southwest Research Institute

SwRI, headquartered in San Antonio, Texas, is one of the oldest and largest independent, nonprofit, applied research and development organizations in the United States. Founded in 1947, SwRI provides contract research and development services to industrial and government clients. The staff of more than 3,300 specializes in the creation and transfer of technology in engineering and the physical sciences. The Institute occupies more than 1,200 acres in San Antonio and provides nearly 2 million square feet of laboratories, test facilities, workshops and offices.

Pre-Academy Activity

Prior to the Academy, you will be asked to complete a pre-assessment. Results will be shared with the lead instructor to help customize the learning experience to specific attendee needs. You will also be sent two articles to read prior to the start of the Academy.

Learning Objectives
By attending this Academy, you will be able to:

  • Articulate basic diesel engine terminology and principles
  • Describe the key features of the basic types of diesel engines
  • Compare various diesel fuel injection systems and their components
  • Analyze the effects of different fuels on engine performance and longevity
  • Compare the function and applicability of various air management systems
  • List the various emission standards and testing requirements
  • Detail the elements of post-combustion emission control devices
  • Discuss emerging diesel engine technologies

Who Should Attend
This academy will be especially valuable for engineers who design diesel engines in the following types of vehicles:

  • Passenger cars
  • Light trucks
  • Heavy trucks
  • Off-highway vehicles
  • Farm machinery

Topical Outline
DAY 1

  • Terminology and Performance Parameters
  • The Case for the Diesel Engine
  • Thermodynamics I
    • First Law
      • Energy balance for a closed system
      • Energy balance for an open system
      • Property Evaluation
    • Second Law
      • Definition of entropy
      • Irreversibility
      • Entropy balance for a closed system
      • Entropy balance for an open system
      • Definition of availability
      • Availability balance
    • Air standard cycle analysis
      • Otto cycle
      • Diesel, Dual, Atkinson, Miller cycles
      • Lessons to be learned from air standard cycles
    • Chemical reactions
      • Stoichiometry (balancing chemical reactions)
      • Definition of equivalence ratio
      • Calculating exhaust gas composition from F/A ratio
      • Calculating F/A ratio from exhaust gas composition
      • Computation of brake specific emissions
    • Energy equation with chemical reactions (combustion reactions)
      • Adiabatic flame temperature
      • Higher/lower heating value
    • Detailed example of energy balance on engine
      • Fuel energy in=coolant + exhaust + work out
    • Fuel Injection Systems
      • Requirements and function
      • Injection timing
      • Injection metering
      • The fuel injection system
      • Types of fuel injection systems and main components
      • Diesel control
        • Mechanical Governor
        • Electronic control systems
      • Nozzle and nozzle holders
      • Application
  • European Diesel Engines
  • Modern Technology Engines & Fuel Systems

DAY 2
  • Fuels Technologies
  • Thermodynamics II: Combustion in Diesel Engines
    • Basic combustion theory - definitions and concepts
    • Complete combustion vs. equilibrium composition (dissociation)
      • Equilibrium assumption vs. kinetics (rate limited reactions)
      • Global vs. elementary reactions
      • Basic flame theory (Ignition, flame propagation & speed, quenching, flammability limits)
      • Autoignition theory
      • Hydrocarbon combustion
      • Laminar and turbulent flame speeds
      • Premixed and diffusion combustion
    • Diesel combustion
      • Phenomenological description of diesel combustion
      • Ignition delay, premixed combustion, diffusion combustion
      • Burning rate diagram (heat release diagram)
    • Combustion chamber design considerations
      • Relationship between air motion, fuel injection system (injection pressure, number of nozzle holes, orifice size), and combustion chamber geometry (bowl size and shape)
    • Modeling the diesel combustion process
      • Fuel-air standard Otto cycle/Diesel cycle (Assumptions, Thermodynamics)
      • Single zone models-heat release type (Assumptions, Thermodynamics)
      • Multi-zone models, phenomenological models
      • CFD modeling
      • Lessons to be learned from each approach
      • Advantages/disadvantages of each approach
    • Heat release analysis
      • Collection of cylinder pressure data (transducers, encoders, data acquisition)
      • Analysis of cylinder pressure data (smoothing, frequency characteristics, mean effective pressure)
      • Heat release model (Krieger and Borman assumptions)
      • Interpretation of heat release diagrams
  • The Role of Lube Oil in Modern Diesel Engines
    • How are Lubricants Specified
    • Viscosity Grades, Quality
    • Lubricant Performance Categories:
    • North America
    • Europe
    • Japan
    • OEM Specifications
    • Future Developments - Low Emission Fluids
    • Composition of Typical Crankcase Lubricants
    • Drivers for Novel Lubricant Development
    • Aftertreatment Compatible Lubricants: SAPS
    • Beyond Current Lubricant Specification - System Approach
  • Diesel Combustion & Emissions in DI Engines
    • Premixed/diffusion combustion
      • Effect of low temperature, low cetane number
      • Effect of turbocharging
    • Factors affecting the combustion process
      • Injection pressure
      • Air swirl
      • Atomization
      • Penetration
      • Drop size distribution
      • Vaporization
      • Ignition delay
    • Combustion influence on fuel economy
      • Effect of heat release
      • Effect of heat transfer -Compare to "adiabatic" engine results
    • Combustion influence on emissions
      • Origin of hydrocarbon emissions
      • Origin of carbon monoxide
      • Origin of NOx emissions
      • Relation to premixed combustion, aromatic content of fuel, cetane number
      • Origin of particulates and smoke
      • Relation to diffusion combustion
      • Effect of fuel sulfur
    • Tradeoffs
      • BSFC vs. NOx
      • NOx vs. particulates
      • HC vs. ignition delay
    • Effect of ignition timing on heat release rate and cylinder pressure
      • Effect of timing of combustion, ignition delay
    • Effect of injection pressure on heat release rate and cylinder pressure
      • Effect of mixing rate on diffusion combustion

DAY 3
  • Engine Controls I
    • Electronic fuel injection system control
    • Control system architectures and hardware
    • Fundamentals of control
    • Design approaches for diesel engine controls
    • Development methods
    • Application requirements
      • Fuel injection volume, timing and rate shaping
  • Engine Controls II
    • Vehicle aspects
    • Ancillary system control and integration
    • Variable geometry turbocharger control
    • EGR scheduling and control
    • Control of other subsystems - today and tomorrow
    • Adaptive controls and the future
  • On-Board Diagnostics
    • Legal Requirements
    • Fault Detection
    • Fault Resolution
    • Diagnostic Tools - OBD and General
    • Future Paths
    • Noise
    • Simulation in Diesel Engines
  • Air Management Systems
    • Turbocharging and supercharging
      • Purpose of turbocharging
      • Supercharging vs. turbocharging
      • Thermodynamic principle of turbocharging
      • Description of turbocharger
      • Performance of turbomachinery (swallowing-lines)
      • Types of turbochargers (fixed, variable, waste-gate)
      • Special arrangements (sequential, turbo compounding)
      • An exercise in turbomatching
      • New role of turbochargers in EGR control
    • Superchargers
      • Mechanically driven
      • Electrically driven
      • Hydraulically driven
      • Role of superchargers in modern diesels
  • In-Cylinder Measures to Control Emissions I and II

DAY 4
  • In-Cylinder Measures to Control Emissions III
  • Diesel Exhaust Aftertreatment I
    • Exhaust system-based emission reduction technologies (aftertreatment)
    • NOx reduction catalysts
    • Selective Catalytic Reduction
      • With Supplemental HC
      • With Urea and Ammonia
    • Lean NOx Traps
    • Diesel Particulate Filters
      • Active Regeneration Systems
      • Passive Regeneration Systems
  • Diesel Exhaust Aftertreatment II
    • Combination Trap/Catalyst Systems
      • Catalyst Assist
      • Catalytically Regenerated Traps
    • Special Aftertreatment Systems
    • Non-Thermal Plasma
    • Non-Thermal Plasma Assisted Catalysts

DAY 5
  • Diesel Exhaust Aftertreatment III
    • Combination Trap/Catalyst Systems
      • Catalyst Assist
      • Catalytically Regenerated Traps
    • Special Aftertreatment Systems
    • Non-Thermal Plasma
    • Non-Thermal Plasma Assisted Catalysts
  • Engine Performance Simulation
  • Emerging Technologies
    • Variable Valve Actuation
    • Camless Valvetrain
  • Emerging Technologies
    • Air Hybrids
    • Other
  • Academy Wrap-up and Evaluation

*The order in which the agenda is presented is subject to change.

Instructor(s): Magdi Khair, Ewa Bardasz, André Boehman, Bernard Challen, Philip Dingle, Michael Levin, and Helmut Tschöeke

Magdi Khair, Lead Instructor, is an Institute Engineer in the Department of Emissions Research at Southwest Research Institute. He is experienced in the areas of engine testing and exhaust emissions control. His prior experience was with AlliedSignal Automotive Catalyst Company with the development of catalytic aftertreatment for light-duty and heavy-duty diesel engines; Ford New Holland with primary responsibility for the development of the 6.6 and 7.8 liter midrange diesel engines to meet 1991 emissions standards; Bendix Diesel Engine Controls where he led the development of advanced electronically controlled diesel fuel injection systems and also established several cooperative engineering programs with European and North American engine manufacturers; and with Chrysler Corporation where he converted the slant six gasoline engine into an open chamber, pilot injected, and electronically controlled diesel engine, supervised a combustion kinetics project, and participated in the design and development of electronic controls for a passenger car turbine engine. Mr. Khair holds 13 U.S. patents in electronic fuel injection, turbocharging, exhaust gas recirculation, and aftertreatment systems. He has also authored and co-authored numerous SAE and ASME papers. Mr. Khair received a B.S. in Automotive Engineering from Ain Shams University, an M.S. in Thermodynamics from the University of Birmingham, England, and an M.B.A. from Michigan State University.

Ewa Bardasz is currently a Principal Scientist at The Lubrizol Corporation. Her work in detailed understanding of lubricant behavior related to corrosion inhibition in petroleum and aqueous systems, structure and performance studies of the metal surface and lubricant interactions, compositions of lubricants for low heat rejection engines, fuel conserving diesel engine lubricants, and lubrication of ceramic surfaces led to numerous technical publications and over 20 patents. She is a member of ACS, SAE, and STLE, Fellow of the Royal Society of Industry and Arts, London, UK and a member of the New York State Academy of Science. Dr. Bardasz received her Ph.D. in Chemical Engineering from The Case Institute of Technology, Cleveland, Ohio.

André Boehman is a Professor of Fuel Science and Materials Science and Engineering in the Department of Energy & Geo-Environmental Engineering in the College of Earth and Mineral Sciences at the Pennsylvania State University, where he has taught courses on Energy, Fuels, Combustion and the Environment since 1994. At the Penn State Energy Institute, Prof. Boehman manages the Diesel Combustion and Emissions Laboratory. Professor Boehman's research interests are in alternative and reformulated fuels, combustion and pollution control. His present research activities are focused on alternative diesel fuels, diesel combustion and diesel exhaust aftertreatment. He is presently on the Editorial Board of Fuel Processing Technology and holds executive positions with the American Chemical Society Division of Fuel Chemistry and with the International DME Association. He has received the 1999 Alumni Achievement Award from the University of Dayton School of Engineering, the 1999 Matthew and Anne Wilson Award for Outstanding Teaching from the Penn State College of Earth and Mineral Sciences and the Philip L. Walker Jr. Faculty Fellowship in Materials Science and Engineering, from 1995-97. He also received the 1986 Charles T. Main Bronze Medal from the American Society of Mechanical Engineers. He has supervised seventeen M.S. theses and five doctoral theses at Penn State, and he has published more than 36 refereed papers and book chapters. He holds a B.S. in Mechanical Engineering from the University of Dayton (1986) and an M.S. (1987) and Ph.D. (1993) in Mechanical Engineering from Stanford University. He held a two-year postdoctoral fellowship in the Molecular Physics Laboratory at SRI International, Menlo Park, California.

Bernard Challen is an independent engineering consultant, active mainly in the automotive industry. His technical areas of interest cover electronics and control, instrumentation, the use of computer-aided engineering tools, and vehicle noise & vibration. Until 1991, he was Technical Director at Ricardo Consulting Engineers where one of his responsibilities was the formation of Ricardo North America. His technical responsibilities within Ricardo covered noise and vibration, instrumentation and control, large engines and the business development of Ricardo in North America. Mr. Challen earned a B.Sc.(Eng.) in Mechanical Engineering and M.Sc. Noise and Vibration, Institute of Sound and Vibration Research, from Southampton University. He is active in a number of professional societies and is a Fellow of the Institution of Mechanical Engineers (IMechE) and also the Institution of Electrical Engineers (IEE). A recipient of the SAE Forest R. McFarland award in 1983, 1990 and 1996, he was elected a Fellow of SAE in 1997. He served as General Chair for the SAE Noise and Vibration Conference from 1992-2003. In 2008, he received the SAE Medal of Honor. In addition to being a regular contributor of technical papers to SAE, he also serves on the Diesel Engine Committee and the Powerplant Governing board.

Philip Dingle is a Diesel Technology Specialist in the advanced engineering Innovation Center of Delphi Diesel Systems. He received his engineering education in England, and after graduating in 1972, joined the Research and Development group of Lucas Diesel Systems where he worked on several advanced engine and fuel system technologies. Transferred to Detroit, USA in 1975, he has worked closely with several US diesel engine manufacturers on the development of FIE for their engines. In the process, he gained broad experience in achieving performance and emissions targets from both DI and IDI combustion systems. He holds twelve US or European patents for fuel system innovation.

Michael Levin holds the position of Technical Expert at Ford Motor Company. Mr. Levin has been with Ford Research and Advanced Engineering since the late 1970s. His current responsibilities include development of hydrocarbon and urea dosing for advanced Diesel aftertreatment systems. Mr. Levin co-authored 18 publications and holds 13 patents. He received his MSME in 1974 from Moscow Automobile and Road Institute in Russia.

Helmut Tschöeke is Professor and Head of the Chair of Reciprocating Machines at the Institute of Mobile Systems at the University of Magdeburg. From 1981 to 1995, he worked with Bosch Diesel Division where he was responsible for research, development and production of distributor and inline pumps, both mechanical and electronically controlled. Dr. Tschöeke also developed distributor-type pumps specifically for DI-engines and did research and development on the solenoid controlled rotary pump VP44. During his career he held positions as department head, chief engineer, and executive plant manager. He is an active member of VDI and member of SAE and the head of a new automotive research program at the University of Magdeburg. Dr. Tschöeke's credentials include the Dipl.-Ing. and Dr.-Ing. from the University of Stuttgart and he was given an honorary doctorate by the Technical University of Kiev.

Fees: $3,145 ; SAE Members: $2,945

4.0 CEUs

Testimonial
"A highlight was hearing and seeing cutting edge research at Ford and having representation from Europe and getting a European perspective on diesel research and direction."

Stephen Beech
Dana Corporation


"Being able to learn from some of the most knowledgeable people in the industry was a fantastic opportunity. I will recommend it for others in my group."

Jeff Morris
Caterpillar Corporation


"This academy has filled in the many gaps I had in my knowledge of diesel engines, as well as those I didn't know I had. Fantastic!"

Chad Mollin
International Truck & Engine Corporation


"This Academy greatly strengthens and increases one's understanding of diesel engine technology and its methods for meeting the demands of industry and environmental regulations. As an engineer relatively new to the diesel engine industry, my competence regarding, and appreciation for, diesel engine technology has improved significantly because of this Academy."

Christopher A. Brown
Senior Project Engineer
Detroit Diesel Corporation

"Impressive! Well worth the investment. A comprehensive introduction to the modern diesel engine."

Jason Lee Jirovsky
Design Engineer
John Deere Power Systems

For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.

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