Development of a Variable Roller Pump and Evaluation of its Power Saving Potential as a Charge Pump in Hydrostatic Drivetrains

Predložená doktorandská dizertačná práca (ďalej len práca) sa zaoberá rozsiahlou analýzou valčekového hydrogenerátora s premenlivým geometrickým objemom a predikciou výkonových úspor dosiahnutých aplikáciou navrhnutého valčekového hydrogenerátora s premenlivým geometrickým objemom v hydrostatickom pohone vybraných mobilných pracovných strojov. Teoretický rozbor princípov fungovania valčekového hydrogenerátora a teória jednorozmerného simulačného modelu sú popísané v prvej časti práce. Na základe odvodenej teórie je vytvorený simulačný model, ktorý je vhodný na predikciu priebehu tlaku v komorách valčekového hydrogenerátora, síl pôsobiacich na valček a na predikciu vnútorných únikov vzniknutých skratovaním rozvodovej dosky, ktoré majú priamy vplyv na objemovú účinnosť valčekového hydrogenerátora. Simulačný model bol úspešne použitý pre optimalizáciu rozvodových dosiek valčekového hydrogenerátora a vhodnosť simulačného modelu potvrdili následné merania Práca obsahuje aj analýzu síl pôsobiacich na vodiaci prstenec, ktorej výsledky boli taktiež potvrdené meraním. Analýza týchto síl môže vylepšiť v konečnom dôsledku parametre budúcich tlakových regulácii. Práca ďalej obsahuje základné porovnanie použitých tlakových regulácii. Všetky uskutočnené merania potvrdili, že valčekový hydrogenerátor s premenlivým geometrickým objemom s testovanými tlakovými reguláciami je schopný úspešne pracovať v hydrostatickej prevodovke. Druhá časť práce analyzuje potenciál výkonových úspor valčekového hydrogenerátora s premenlivým geometrickým objemom pre dve mobilné aplikácie - teleskopický nakladač s hmotnosťou 9 ton a kombajn s hmotnosťou 20 ton. Analýza vyžaduje jednorozmerný simulačný model hydrostatického pohonu s teplotnou predikciou hydrostatickej prevodovky. Dva rozdielne koncepty variabilného doplňovacieho systému hydrostatickej prevodovky sú porovnané so štandardným doplňovacím systémom pre pracovný a transportný režim oboch vybraných typov vozidiel. Simulácia pohonu vozidla s valčekovým hydrogenerátorom s premenlivým geometrickým objemom vo funkcii doplňovacieho hydrogenerátora a obtokovou clonou potvrdili vyššie úspory iba v prípadoch, kedy rýchlosť doplňovacieho hydrogenerátora bola výrazne vyššia a prietok cez obtokovú clonu do skrine hlavného hydrogenerátora zabezpečil dostatočné chladenie. Najvyššie výkonové úspory boli dosiahnuté s premenlivým preplachovacím systémom, ktorého prietok sa menil podľa požiadaviek hydrostatickej prevodovky. Záver druhej časti práce sa zaoberá metodikou dimenzovania veľkosti doplňovacieho hydrogenerátora.Presented doctoral thesis deals with an extensive hydraulic variable roller pump analysis and the power saving prediction of hydrostatic drivetrains in the mobile machines achieved with a variable roller charge pump implementation. At the first part of the work, the roller pump functionality was described and the theory of a 1-D simulation model was developed. Based on this developed simulation model is suitable for pressure profile prediction, roller force prediction and cross port leakage prediction which has a direct impact on the total volumetric efficiency. The simulation model was successfully used as a tool for optimization of the port plates, which was confirmed by measurements. The first part of the work includes the pump control force analysis validated by measurements and also the basic pressure compensator controls comparison. Developed control force prediction could help to improve the control performance. The measurements confirmed that the variable roller charge pump is able to successfully work in transmissions with measured types of the control. The second part of the work analyzed the power saving potential of a variable charge pump for two selected typical mobile applications: telehandler (9 ton) and combine harvester (20 ton). This part required a 1-D drivetrain simulation model together with thermal behaviour of the hydrostatic transmission. Two different modifications of the charging systems were compared with the conventional charging system in simulations performed for the working and transporting mode. The drivetrain simulation of the variable roller charge pump with a bypass orifice confirms higher power savings only in cases when the pump speed was significantly higher than normal speeds and a relatively constant flushing flow through the bypass orifice to the pump case still ensures suitable cooling. The highest power savings were achieved with variable flushing flows, where the demand for charging flow was adjusted according to the hydrostatic transmission cooling requirements. At the end of the second part, this thesis deals with a variable charge pump sizing.

The digital simulation of a turbo-charged diesel engine

A mathematical simulation of a six cylinder four stroke water cooled diesel engine is described and then used to study the changes in performance caused by variations of engine paramters and operating conditions. The results are discussed with reference to the mathematical model employed and the physical system. A limited study, to demonstrate the applicability of the simulation, considers the optimisation of a variable geometry system to achieve a performance target

Investigation of cylinder deactivation and variable valve actuation on gasoline engine performance

Increasingly stringent regulations on gasoline engine fuel consumption and exhaust emissions require additional technology integration such as Cylinder Deactivation (CDA) and Variable valve actuation (VVA) to improve part load engine efficiency. At part load, CDA is achieved by closing the inlet and exhaust valves and shutting off the fuel supply to a selected number of cylinders. Variable valve actuation (VVA) enables the cylinder gas exchange process to be optimised for different engine speeds by changing valve opening and closing times as well as maximum valve lift. The focus of this study was the investigation of effect of the integration of the above two technologies on the performance of a gasoline engine operating at part load conditions. In this study, a 1.6 Litre in-line 4-cylinder gasoline engine is modelled on engine simulation software and simulated data is analysed to show improvements in fuel consumption, CO2 emissions, pumping losses and effects on CO and NOx emissions. A CDA and VVA operating window is identified which yields brake specific fuel consumption improvements of 10-20% against the base engine at engine speeds between 1000rpm to 3500rpm at approximately 12.5% load. Highest concentration of CO emissions was observed at between 4 to 5 bar BMEP at 4000rpm and highest concentration of NOx at the same load range but at 1000rpm.Findings based on simulation results point towards significant part load performance improvements which can be achieved by integrating cylinder deactivation and variable valve actuation on gasoline engines. Copyright © 2014 SAE International

Lightweight, low compression aircraft diesel engine

The feasibility of converting a spark ignition aircraft engine to the diesel cycle was investigated. Procedures necessary for converting a single cylinder GTS10-520 are described as well as a single cylinder diesel engine test program. The modification of the engine for the hot port cooling concept is discussed. A digital computer graphics simulation of a twin engine aircraft incorporating the diesel engine and Hot Fort concept is presented showing some potential gains in aircraft performance. Sample results of the computer program used in the simulation are included

A comparison of variable valve strategies at part load for throttled and un-throttled SI engine configurations

The presented work concerns the study of the fuel consumption and emissions benefits achieved at part load by employing a fully variable valve train in a 1.6L SI gasoline engine. The benefits achieved when using variable valve timing alone, and combined with an early intake closing strategy for un-throttled operation were explored in order to highlight the merits of throttle versus un-throttled engine operation in conjunction with variable valve timing and lift. In addition, particular interest was given to the presence of internal Exhaust Gas Recirculation (EGR) and its ability to reduce pumping loss at part load. An engine model employing multiple sub models to handle variable valve operation was constructed using a commercial gas dynamics engine code, allowing detailed analysis of three valve strategies. Using the engine model, a theoretical study validated by experimentally available data was carried out to study key valve timing cases. A detailed breakdown of the mechanisms present in each case allowed a comprehensive understanding of the influence of valve timing on gas exchange efficiency and fuel consumption

Direct comparasion of an engine working under Otto, Miller end Diesel cycles : thermodynamic analysis and real engine performance

One of the ways to improve thermodynamic efficiency of Spark Ignition engines is by the optimisation of valve timing and lift and compression ratio. The throttleless engine and the Miller cycle engine are proven concepts for efficiency improvements of such engines. This paper reports on an engine with variable valve timing (VVT) and variable compression ratio (VCR) in order to fulfill such an enhancement of efficiency. Engine load is controlled by the valve opening period (enabling throttleless operation and Miller cycle), while the variable compression ratio keeps the efficiency high throughout all speed and load conditions. A computer model is used to simulate such an engine and evaluate its improvement potential, while a single cylinder engine demonstrates these results. The same base engine was run on the test bench under the Diesel cycle, Otto cycle and Miller cycle conditions, enabling direct thermodynamic comparisons under a wide variety of conditions of speed and load. The results show a significant improvement of the Miller cycle over the Otto cycle engine. Comparisons of the Miller engine with the Diesel engine shown that it is possible to have a SI engine with better efficiency than a similar Diesel engine for most of the working conditions.Fundação para a Ciência e a Tecnologia (FCT) e Fundo Social Europeu (FSE) - SFRH/BD/11194/2002, FCT/FEDER POCI/ENR/59168/2004, POCI/EME/59186/200

Catalog of selected heavy duty transport energy management models

A catalog of energy management models for heavy duty transport systems powered by diesel engines is presented. The catalog results from a literature survey, supplemented by telephone interviews and mailed questionnaires to discover the major computer models currently used in the transportation industry in the following categories: heavy duty transport systems, which consist of highway (vehicle simulation), marine (ship simulation), rail (locomotive simulation), and pipeline (pumping station simulation); and heavy duty diesel engines, which involve models that match the intake/exhaust system to the engine, fuel efficiency, emissions, combustion chamber shape, fuel injection system, heat transfer, intake/exhaust system, operating performance, and waste heat utilization devices, i.e., turbocharger, bottoming cycle

Combining Unthrottled Operation with Internal EGR under Port and Central Direct Fuel Injection Conditions in a Single Cylinder SI Engine

This experimental work was concerned with the combination of internal EGR with an early inlet valve closure strategy for improved part-load fuel economy. The experiments were performed in a new spark-ignited thermodynamic single cylinder research engine, equipped with a mechanical fully variable valvetrain on both the inlet and exhaust. During unthrottled operation at constant engine speed and load, increasing the mass of trapped residual allowed increased valve duration and lift to be used. In turn, this enabled further small improvements in gas exchange efficiency, thermal efficiency and hence indicated fuel consumption. Such effects were quantified under both port and homogeneous central direct fuel injection conditions. Shrouding of the inlet ports as a potential method to increase in-cylinder gas velocities has also been considered. Copyright © 2009 SAE International