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Outline

Title
Abstract
Key Takeaways
Figures
Introduction
Engine Rig Design
Results
Conclusion
References
All Topics
Engineering
Mechanical Engineering

Digital twin of an internal combustion engine

Profile image of German De Melo RodriguezGerman De Melo Rodriguez

2020

Abstract

Major marine engine companies such as Wartsila have developed both their new 4-stroke and 2-storke using gas and hence strongly believe that Internal Combustion Engines (ICE) have a place in marine power propulsion and auxiliary units. A recent announcement that Mazda sees a bright future for ICE is also indicative of the automotive industry has not lost hope in the future of ICE. This paper reports on recent developments to construct a digital twin of these power units with a view to improve their performance and also as a means of monitoring their behaviour when changes are introduced. This paper is composed of two parts. Part 1 is the digital half of an Internal Combustion Engine (ICE) which concerns the development of a mathematical model of the ICE and a suite of computer simulation programs which would allow the effects of various design and operational changes to be reliably and accurately predicted with the ultimate aim of producing cleaner engines and/or more efficient power units. The model has been tested against the experimental results of the Paxman engine at Newcastle University and earlier against the Atlas engine at Ricardo, Brighton, UK and most recently on the TUDEV Engine (2015). Part 2, contains the other digital half of the ICE which describes the rig developments viz., the physical model of an Engine. The key features of both Parts of the paper will e presented at the conference due to commercial confidentiality. However, the idea is to match the two parts using an earlier model developed by Ziarati (2009) to produce a finger print of both the mathematical model and the physical model. The matching of both parts would enable the mathematical model to be used for various design and operational changes with a view to reduce fuel consumption and/or engine harmful emissions. The predicted results and the experimental data are in good agreement.

Key takeaways
sparkles

AI

  1. The paper focuses on developing a digital twin model for internal combustion engines (ICE) to enhance performance.
  2. The mathematical model has been validated against engines like Paxman and TUDEV, showing good agreement with experimental data.
  3. Key programs include the 'Element Mixing Program' and 'Heat Release' for analyzing combustion processes.
  4. Using a digital twin significantly reduces costs and time in engine design and development.
  5. Diesel-gas combinations prove effective in improving thermal efficiency and reducing harmful emissions during high load operations.
Figures (29)
Figure 2 Piston Travel
Figure 2 Piston Travel
If the seat angle is assumed to be 60°, the truncated cone A‘, equals to: Figure 4 Valve Seat Presentation (Ziarati, 1991) This program can be used only when practical injection diagrams are considered. Rate of injection program calculates the rate of fuel injected at specified crank angle. The annular area between the needle and the seat and total nozzle holes area are assumed to be two orifices in series. Knowledge of the line pressures Pr, cylinder pressures Cp and needle lifts L for specified crank angles for any given step enables the rate to be calculated:
If the seat angle is assumed to be 60°, the truncated cone A‘, equals to: Figure 4 Valve Seat Presentation (Ziarati, 1991) This program can be used only when practical injection diagrams are considered. Rate of injection program calculates the rate of fuel injected at specified crank angle. The annular area between the needle and the seat and total nozzle holes area are assumed to be two orifices in series. Knowledge of the line pressures Pr, cylinder pressures Cp and needle lifts L for specified crank angles for any given step enables the rate to be calculated:
Table 1 Research Engine Specifications. Table 2 Theoretical and Experimental Results (Ziarati, 1991)
Table 1 Research Engine Specifications. Table 2 Theoretical and Experimental Results (Ziarati, 1991)
As can be seen from Figure 5, all necessary outputs are calculated and cylinder pressure, cylinder temperature, heat release data are predicted. Also, wall impingement time, heat loss and air entrainment are shown. Figure 5 Output Screenshot of Element Mixing Program.
As can be seen from Figure 5, all necessary outputs are calculated and cylinder pressure, cylinder temperature, heat release data are predicted. Also, wall impingement time, heat loss and air entrainment are shown. Figure 5 Output Screenshot of Element Mixing Program.
Figure 6 Output Screenshot of Heat Release Program.
Figure 6 Output Screenshot of Heat Release Program.
Figure 9 Predicted and Experimental Heat Release. The application of diesel engines in automotive and marine industries and its use as stand alone power units have been rapidly increasing in recent years mainly due to the development and applications of new technologies. These developments on diesel engines are focused on the performance increase and the emission control. To increase the performance, higher thermal efficiency and to control the emission, lower toxic gases
Figure 9 Predicted and Experimental Heat Release. The application of diesel engines in automotive and marine industries and its use as stand alone power units have been rapidly increasing in recent years mainly due to the development and applications of new technologies. These developments on diesel engines are focused on the performance increase and the emission control. To increase the performance, higher thermal efficiency and to control the emission, lower toxic gases
Table 3 Specifications of the engine, generator, piezoelectric sensor and data acquisition card.
Table 3 Specifications of the engine, generator, piezoelectric sensor and data acquisition card.
Table 4 Specifications of the emission measurement devices.
Table 4 Specifications of the emission measurement devices.
A dual-core cpu computer and two 19” monitors are used in the control room. A user friendly user interface algorithm was prepared using Labview ® which has flexible, powerful and attractive tools for algorithm design. Block diagram of the laboratory is shown in Fig. 10. In addition to that emission measurement devices were set up to measure and track the values of CO, NOx, COz, O2 and THC at the various diesel engine operating conditions. Technical specifications of the emission measurement devices are given in Table 4.
A dual-core cpu computer and two 19” monitors are used in the control room. A user friendly user interface algorithm was prepared using Labview ® which has flexible, powerful and attractive tools for algorithm design. Block diagram of the laboratory is shown in Fig. 10. In addition to that emission measurement devices were set up to measure and track the values of CO, NOx, COz, O2 and THC at the various diesel engine operating conditions. Technical specifications of the emission measurement devices are given in Table 4.
Buttons of engine speed (rpm), fuel level (“%), fuel flow (kg/h), air flow rate(kg/h), air/fuel ratio, torque (Nm), power (kW), air temperature (°C), status window are installed on the indicator panel. To take the exact value of the data both numerical and analog results are displayed on the panel at the same time. The indicator panel is refreshed after all measurements completed. Status window provides users instructions and information about progress. The indicator and control panels are shown in Fig.11.
Buttons of engine speed (rpm), fuel level (“%), fuel flow (kg/h), air flow rate(kg/h), air/fuel ratio, torque (Nm), power (kW), air temperature (°C), status window are installed on the indicator panel. To take the exact value of the data both numerical and analog results are displayed on the panel at the same time. The indicator panel is refreshed after all measurements completed. Status window provides users instructions and information about progress. The indicator and control panels are shown in Fig.11.
Figure 12. Block diagram of cylinder pressure. Figure 13. Graph of the MAF output measurement.
Figure 12. Block diagram of cylinder pressure. Figure 13. Graph of the MAF output measurement.
Since single cylinder diesel engine is used, some amount of suction air returns back to the surge tank again. Therefore, both suction and backward air flows are measured accurately to calculate the correct inflow to the cylinder. Suction signal frequency has to be the half of the engine speed frequency. Therefore, the MAF output is examined in frequency spectrum to realize filter for return signal. To measure inflow, low pass filter whose cut- off frequency is changed according to engine speed is added into the program. Cut-off frequency is adjusted between 8 and 25 Hz while engine speed frequency is between 16 and 50 Hz. A thermistor in the MAF is used with Wheatstone bridge to measure inlet air temperature. Frequency spectrum of MAF output is shown in
Since single cylinder diesel engine is used, some amount of suction air returns back to the surge tank again. Therefore, both suction and backward air flows are measured accurately to calculate the correct inflow to the cylinder. Suction signal frequency has to be the half of the engine speed frequency. Therefore, the MAF output is examined in frequency spectrum to realize filter for return signal. To measure inflow, low pass filter whose cut- off frequency is changed according to engine speed is added into the program. Cut-off frequency is adjusted between 8 and 25 Hz while engine speed frequency is between 16 and 50 Hz. A thermistor in the MAF is used with Wheatstone bridge to measure inlet air temperature. Frequency spectrum of MAF output is shown in
Figure 14. Frequency spectrum of suction. Figure 15. Block diagram of the air flow measurement and return flow signals.
Figure 14. Frequency spectrum of suction. Figure 15. Block diagram of the air flow measurement and return flow signals.
Figure 16 Block diagram of the fuel flow measurement 8.4 TORQUE AND POWER MEASUREMENTS. A loadcell is mounted to DC generator’s frame to measure torque. Its technique is based on that armature current being consumed by load resistances is directly proportional to rotational force of field winding fixed generator body. Torque values are filtered by low pass filter whose cut-off frequency is 10 Hz to reduce noise due to engine vibration. Torque is calculated by multiplying the force on the loadcell and the arm length. Torque and power are calculated as follows:
Figure 16 Block diagram of the fuel flow measurement 8.4 TORQUE AND POWER MEASUREMENTS. A loadcell is mounted to DC generator’s frame to measure torque. Its technique is based on that armature current being consumed by load resistances is directly proportional to rotational force of field winding fixed generator body. Torque values are filtered by low pass filter whose cut-off frequency is 10 Hz to reduce noise due to engine vibration. Torque is calculated by multiplying the force on the loadcell and the arm length. Torque and power are calculated as follows:
Table 6 Sample measurements.
Table 6 Sample measurements.
The research facility is fully instrumented using a range of sensors and a computerized data processing and analysis system and it is capable of computing diesel engine performance characteristics. Results of measurements are obtained using the graphical user interface in the control room. With the help of user friendly properties of the graphical user interface, any further test procedures can be programmed. Sample measurement results are given in Table 6.
The research facility is fully instrumented using a range of sensors and a computerized data processing and analysis system and it is capable of computing diesel engine performance characteristics. Results of measurements are obtained using the graphical user interface in the control room. With the help of user friendly properties of the graphical user interface, any further test procedures can be programmed. Sample measurement results are given in Table 6.
Figure 21 rpm versus power.
Figure 21 rpm versus power.

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Sergey Karianskyi

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The marine medium-speed diesel engine operating-condition parameters can be used for developing or correcting the special-purpose ship's main power plant simulator characteristics. Monitoring of the performance of four main engines installed on the m/v "Greifswald" was carried out during the voyage that took place in January 2015 on the "Odessa-Istanbul-Odessa" navigation line. The existing weather conditions permitted, while maintaining an equal load on the engines, to carry out a parametrical diagnosis of all the main-engine cylinders, including the diagnosis of the high pressure fuel injection equipment (FIE), valves timing gears (VTG) and cylinder piston groups (CPG). The D4.OH (DEPAS) computer-based diagnosis system was used for determining of the operating-condition parameters. Due to the fact that the D4.OH system uses the methods of data algorithmic synchronization, vibration and acoustic determination of the fuel injection and gas distribution parameters, it is a convenient means for diagnosing medium-speed diesel engines, which are not fitted with any power actuator to be used for taking indicator diagrams. Diagnostics data obtained enable to improve the accuracy of the marine power plant simulator characteristics, as well as to monitor the status of CPGs, and repair deficiencies in FIE and VTG. D4.OH-assisted determination and further uniform distribution of the power among the engine cylinders gives a possibility to equalize heat and mechanical loads. All the carried out procedure package has promoted lowering of the general level of vibration and heat-release rate in the CPG parts, a reduction of the specific fuel consumption, a service-life rise, a decrease of the risk of an emergency occurrence in the course of the ship's operation. Interrelationships among the parameters are taken into account when developing marine power plant simulators.

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Physics-Based Diesel Engine Model Development, Calibration and Validation for Accurate Cylinder Parameters and Nox Prediction
Ali Razban

2021

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McGraw-Hill Series in Mechanical Engineering INTERNAL COMBUSTION ENGINE Xnderung nur iiber
Victor Ribeiro

areas of thermodynamics, combustion, energy, power, and propulsion. During the past two decades, his research activities have centered on the operating characteristics and fuels requirements of automotive and aircraft engines. A major emphasis has been on computer models which predict the performance, efficiency, and emissions of spark-ignition, diesel, and gas turbine engines; and in carrying out experiments to develop and validate these models. He is also actively involved in technology assessments and policy studies related to automotive engines, automobile fuel utilization, and the control of air pollution. He consults frequently in &he automotive and petroleum industries, and for the U.S. Government.

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