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Technical Paper

“Cromard” Thin Wall Steel Liners and Hard Chrome Plated Liners for High Production Gasoline and Diesel Engines

This paper, confined to the application of hard chrome plated liners to high-speed four-stroke diesel and gasoline engines, illustrates the increase in their popularity in the United Kingdom, and the advanced production methods which make this economically possible. The need for balanced engine life has long been apparent and is even more important today, the growth of motor transport having outstripped repair facilities. Iron bore life has been surpassed by improvement in the life of other component parts in the modern diesel engine. The provision of hard chrome plated liners can restore the balance. Further development and turbocharging of diesel engines has shown the need for a bore material capable of preventing scuffing and galling at elevated temperatures. Hard chrome has already proved itself in four-stroke engines under these conditions.
Technical Paper

“Catalytic Engine” NOx Reduction of Diesel Engines with New Concept Onboard Ammonia Synthesis System

Ammonia is one of the most useful compounds that react with NOx selectively on a catalyst, such as V2O5-TiO2, under oxygen containing exhaust gas. However ammonia cannot be stored because of its toxicity for the small power generator in populated areas or for the diesel vehicles. A new concept for NOx reduction in diesel engine using ammonia is introduced. This system is constructed from the hydrogen generator by fuel reformer, the ammonia synthesizer, SCR catalyst for NOx reduction and the gas injection system of reformed gas into the cylinder. Experimental results show that, the SCR catalyst provides a very high rate of NOx reduction, reformed gas injection into cylinder is very effective for particulate reduction. WHEN CONSIDERING INTERNAL COMBUSTION ENGINES of the 1990's the question of how to harmonize the engine with the natural environments is one of the greatest problems. The internal combustion engine changes a substance into energy via its explosive combustion.
Technical Paper

“Buckling” Failure Assessment for Long Cylinders

A new method for the structural study of long hydraulic cylinders has been developed. The rational analysis, taking cognizance of most known conditions and disturbances, is capable of an iterative type solution by computer. Some examples of its use are given, illustrating the effects of stroke length and mounting position on stresses, deflections, internal bearing loads, and critical axial load.
Technical Paper

“All Electric” Controls and Accessories for Ground Vehicle Gas Turbine Propulsion Systems

This paper discusses the use of electromechanical devices as the kinematic portions of a microprocessor based gas turbine control system. Specific applications are: 1. An electric motor driven, positive displacement pump, which provides metered high pressure fuel to the distribution manifold. Fuel metering to be provided by varying the motor angular velocity. 2. An electric motor driven lube oil pump. 3. Electromechnical actuators for motion and control of compressor and power turbine variable geometry. 4. A starter/generator integral with the gas generator. Topics covered include: Comparison to conventional hydro-mechanical systems. Response characteristics of the fuel pump and actuator systems. Brushless D.C. motor characteristics. Power electronics requirements for brushless D.C. motors. Control electronics interface with brushless D.C. motor systems. Reliability and maintainability issues. Diagnostic/prognostic enhancements.
Technical Paper

‘Bigelow Aerospace® Life Support Laboratory - Planning and Status’

This Life Support Laboratory consists of a simulator of the spacecraft called Nautilus, which houses Air Revitalization Subsystem, Atmospheric Control and Supply, and Fire Detection and Suppression in the Equipment Area. There are supporting facilities including a Human Metabolic Simulator, simulated Low and Moderate Temperature Coolant Loop, chemical analysis bench, purified water supply, vacuum and gas supplies. These facilities are scheduled to be completed and start to operate for demonstration purposes by March 2005. There are an ARES Ground Model (AGM) and a Trace Contaminant Control Assembly in the ARS. The latter will be integrated with the AGM and a Condensing Heat Exchanger. The unit of AGM is being engineered, built, and will be delivered in early 2005 by EADS Space Division. These assemblies will be operated for sensitivity analysis, integration and optimization studies. The main goal is the achievement for optimal recovery of oxygen.
Technical Paper

λDSF: Dynamic Skip Fire with Homogeneous Lean Burn for Improved Fuel Consumption, Emissions and Drivability

Dynamic skip fire (DSF) has shown significant fuel economy improvement potential via reduction of pumping losses that generally affect throttled spark-ignition (SI) engines. In DSF operation, individual cylinders are fired on-demand near peak efficiency to satisfy driver torque demand. For vehicles with a downsized-boosted 4-cylinder engine, DSF can reduce fuel consumption by 8% in the WLTC (Class 3) drive cycle. The relatively low cost of cylinder deactivation hardware further improves the production value of DSF. Lean burn strategies in gasoline engines have also demonstrated significant fuel efficiency gains resulting from reduced pumping losses and improved thermodynamic characteristics, such as higher specific heat ratio and lower heat losses. Fuel-air mixture stratification is generally required to achieve stable combustion at low loads.
Technical Paper

µMist® - The next generation fuel injection system: Improved atomisation and combustion for port-fuel-injected engines

The Swedish Biomimetics 3000's μMist® platform technology has been used to develop a radically new injection system. This prototype system, developed and characterized with support from Lotus, as part of Swedish Biomimetics 3000®'s V₂IO innovation accelerating model, delivers improved combustion efficiency through achieving exceptionally small droplets, at fuel rail pressures far less than conventional GDI systems and as low as PFI systems. The system gives the opportunity to prepare and deliver all of the fuel load for the engine while the intake valves are open and after the exhaust valves have closed, thereby offering the potential to use advanced charge scavenging techniques in PFI engines which have hitherto been restricted to direct-injection engines, and at a lower system cost than a GDI injection system.
Technical Paper

the use of Radioactive Tracer Techniques to determine the effect of operating variables on Eng ine Wear

RADIOTRACERS were used to study the wear effects of engine speed, load, jacket water temperature, fuel temperature, and chromium-plated rings in a medium-speed diesel engine. One distillate fuel and two residual fuels were tested. This paper describes the tests and their results. Some of the conclusions are: The brake thermal efficiency with high viscosity residual fuel was essentially equal to distillate diesel fuel over a wide range of loads, providing the residual fuel was heated to the proper temperature. Engine speed did not affect the wear rate of cast-iron rings when distillate fuel was used, while with residual fuel wear decreased with increased speed. With distillate fuel, engine load had essentially no effect on cast-iron ring wear. With residual fuel, decreasing engine load produced a marked increase in ring wear*
Technical Paper

the potential of Unconventional Powerplants for Vehicle Propulsion

COMPARISON of work capacity per unit mass and volume of different energy carriers shows that liquid hydrocarbons are superior to other energy sources. Solar and nuclear powerplants as well as their use in conjunction with a steam engine are examined in this paper. Suitability of an electric drive is discussed. Using a production 2-stroke diesel engine and its development forecast, a comparison is made of spark ignition, diesel, and gas turbine engines. The status of the free-piston engine turbine combination is reviewed.
Technical Paper

the identification and characterization of RUMBLE AND THUD

SIMULTANEOUS RECORDINGS of cylinder pressure, audible sound, and crankshaft motion have shown that rumble is a noise associated with bending vibrations of the crankshaft. The vibrations are caused by abnormally high rates of pressure rise near the top dead center piston position. In this study the high rates of pressure rise were obtained by inducting deposits into the the engine. Thud is a torsional vibration of the crankshaft, similar in sound to rumble but resulting from much earlier occurrence of the maximum rates of pressure rise. Rumble vibrations consisted of a fundamental frequency of 600 cps and higher harmonics in the 11/1 compression ratio V-8 laboratory engine used in the investigation. The audible noise of rumble was predominantly composed of the second harmonic or about 1200 cps.
Technical Paper

some metallurgical aspects of … Pontiac V-8 Engine Pearlitic Malleable Iron Crankshaft

PEARLITIC malleable iron crankshafts are being used in the new Pontiac engine as a result of recent developments. This paper discusses the physical properties of pearlitic malleable iron such as elastic modulus, fatigue endurance, and tensile strength. According to the author, definite machining economies result from using pearlitic malleable iron crankshafts.
Technical Paper

some development problems with Large Cryogenic Propellant Systems

HEAT TRANSFER causes loading and starting design problems in large missile systems powered by cryogenic propellants. This manifests itself during loading as effective density variation, violent surface conditions, boiloff, and ice formation — problems which may be solved by insulating the tank. During starting it causes overheating and caviation — effects which may be reduced by recirculators and subcooled charge injections. The study described in this paper centers around liquid oxygen and its variations in heat flux rate, which affect liquid density, surface condition, and replenishing requirements. The problem areas are made apparent by consideration of a hypothetical missile system.*
Technical Paper

p>Thermomechanical Analysis of the Cylinder Head and Cylinder Block with the Liner of AFV Diesel Engine

This paper deals with the Coupled thermo mechanical analysis of a cylinder head, cylinder block and crank case with the liner of an uprated engine. The existing engine develops 780 hp output with mechanical driven supercharger and the engine is uprated to 1000 hp by replacing the supercharger with a turbocharger and new Fuel injection equipment. For uprating any engine, the piston and cylinder head are the most vulnerable members due to increased mechanical and thermal loadings. Mechanical loading is due to the gas pressure in the gas chamber and its magnitude can be judged in terms of peak pressure. Thermal loading is due to temperature and the heat transfer conditions in the piston surface, cylinder liner and the cylinder head. The relative importance of the various loads applied on the head and cylinder block in operation are assessed and a method of predicting their influence on the structural integrity of the components described.
Technical Paper

modeFRONTIER for Virtual Design and Optimization of Compact Heat Exchangers

The main purpose of this study is the development of an innovative methodology for Heat Exchangers (HE) design to replace the conventional design procedures. The new procedure is based on the definition of a software package managed by modeFRONTIER, a multi-objective optimization software produced by ESTECO, able to create HE virtual models by targeting several objectives, like HE performance, optimal use of material, HE minimal weight and size and optimal manufacturability. The proposed methodology consists first in the definition of a workflow for the automatic CFD simulation of a parametric model of a periodic HE cellular element.
Technical Paper

mDSF: Improved Fuel Efficiency, Drivability and Vibrations via Dynamic Skip Fire and Miller Cycle Synergies

mDSF is a novel cylinder deactivation technology developed at Tula Technology, which combines the torque control of Dynamic Skip Fire (DSF) with Miller cycle engines to optimize fuel efficiency at minimal cost. mDSF employs a valvetrain with variable valve lift plus deactivation and novel control algorithms founded on Tula’s proven DSF technology. This allows cylinders to dynamically alternate among 3 potential states: high-charge fire, low-charge fire, and skip (deactivation). The low-charge fire state is achieved through an aggressive Miller cycle with Early Intake Valve Closing (EIVC). The three operating states in mDSF can be used to simultaneously optimize engine efficiency and driveline vibrations. Acceleration performance is retained using the all-cylinder, high-charge firing mode.
Technical Paper

knock-knock: Spark Knock, Wild Ping, or Rumble?

ENGINE noise has become an increasing problem with the higher and higher compression ratios of present-day automotive engines. Because fuel octane number cannot be raised indefinitely, the problem is one of engine design and selection of crankcase lubricating oils and gasoline formulations, the authors think. This paper describes investigations into the cause of spark knock, wild ping, rumble, and the added problem of hot-spot surface ignition (which also intensifies as compression ratios increase). The authors have found gasolines with phosphorous additives, used with properly formulated multiviscosity lubricating oils, provide a partial answer to the problem of engine rumble. The authors conclude that very exact tailoring of fuels, lubricants, additives, and engines will be necessary to prevent engine noise if compression ratios continue to rise.