NomeNclature INtroductIoNDiesel engines will continue to be the prime-movers of future battle tanks owing to their fuel economy, high torque and ease of maintenance. Common rail direct injection (CR DI) technology with electronic engine control is likely to overcome the challenges imposed by extreme weather conditions and other hazards like zero visibility dusty terrains and will replace present mechanical fuel injection systems in the battle tank. Modelling of a turbocharger is of interest to the engine designer as the work developed by the turbine can be used to drive a compressor coupled to it. This positively influences charge air density and engine power to weight ratio. Variable geometry turbocharger (VGT) additionally has a controllable set of nozzles which through a ring is normally electropneumatically actuated by the engine control unit (ECU). This additional degree of freedom offers efficient matching of the effective turbine area for a wide range of engine mass flow rates. At the design point, nozzle less turbine is generally 7 per cent less efficient than the turbine with nozzle blades whereas at off design points it performs better than turbine with nozzle blades 1 . Using VGT, this loss in efficiency can be reduced by matching incidence gas flow angle at the turbine rotor entry to the optimum incidence angle thereby reducing incidence loss which is a major loss at off design operation as proven by experimental studies in 2 . Hence, a CR DI engine with electronic control and VGT offers the advantage of closely matched engine-turbocharger coupled operation at all operating points. But multivariable nature of this control problem makes the system complex and makes control strategies and controller design complicated. In the conventional approach, a map of boost pressure as a function of engine speed and throttle Simulation of a diesel engine with Variable Geometry turbocharger and Parametric Study of Variable Vane Position on engine PerformanceAnand Mammen Thomas #,* , Jensen Samuel J. Modelling of a turbocharger is of interest to the engine designer as the work developed by the turbine can be used to drive a compressor coupled to it. This positively influences charge air density and engine power to weight ratio. Variable geometry turbocharger (VGT) additionally has a controllable nozzle ring which is normally electropneumatically actuated. This additional degree of freedom offers efficient matching of the effective turbine area for a wide range of engine mass flow rates. Closing of the nozzle ring (vanes tangential to rotor) result in more turbine work and deliver higher boost pressure but it also increases the back pressure on the engine induced by reduced turbine effective area. This adversely affects the net engine torque as the pumping work required increases. Hence, the optimum vane position for a given engine operating point is to be found through simulations or experimentation. A thermodynamic simulation model of a 2.2l 4 cylinder diesel engine was developed for investigation of different con...
Mean-line modelling approach which has generally been applied to fixed geometry turbocharger turbines has been extended to predict the performance of the variable geometry turbine for different inlet blade angles. The model uses an initial assumption of turbine inlet pressure which was iteratively corrected based on outlet pressure boundary condition. The model was implemented in MATLAB and stable and convergent solutions were obtained using relaxation techniques for different operating conditions. Experiments were done on a state of the art transient diesel engine test bed using the same VGT turbine in the turbocharger at different engine torques and speeds. Using experimental data the model was calibrated for the aerodynamic blockage in the fixed nozzle and rotor blade passages. Results revealed that turbine overall pressure ratio can be predicted accurately if a blockage factor varying with nozzle blade orientation is used in the model.
Conventionally diesel engines are controlled in open loop with maps based on engine speed and throttle position wherein fuel quantity is indirectly fixed using the rail pressure and injection duration maps with engine speed and throttle position as the independent variables which are measured by the respective sensors. In this work an engine control unit (ECU) software architecture where fuel quantity is directly specified in relation to the driver demand was implemented by modifying the control logic of a throttle position based framework. A desired fuel quantity for a given engine speed and throttle position was mapped from base line experiments on the reference engine. Injection durations and rail pressure required for this quantity was mapped on a fuel injector calibration test bench. The final calculation of injection duration in the new architecture is calculated using the fuel injector model. This enables determination of fuel quantity injected at any moment which directly indicates the torque produced by the engine at a given speed enabling smoke limited fuelling calculations and easing the implementation of control functions like all-speed governing.
The development of a controller which can be used for engines used in armoured fighting vehicles is discussed. This involved choosing a state of the art reference common rail automotive Diesel engine and setting-up of a transient engine testing facility. The dynamometer through special real-time software was controlled to vary the engine speed and throttle position. The reference engine was first tested with its stock ECU and its bounds of operation were identified. Several software modules were developed in-house in stages and evaluated on special test benches before being integrated and tested on the reference engine. Complete engine control software was thus developed in Simulink and flashed on to an open engine controller which was then interfaced with the engine. The developed control software includes strategies for closed loop control of fuel rail pressure, boost pressure, idle speed, coolant temperature based engine de-rating, control of fuel injection timing, duration and number of injections per cycle based on engine speed and driver input. The developed control algorithms also facilitated online calibration of engine maps and manual over-ride and control of engine parameters whenever required. The software was further tuned under transient conditions on the actual engine for close control of various parameters including rail pressure, idling speed and boost pressure. Finally, the developed control strategies were successfully demonstrated and validated on the reference engine being loaded on customised transient cycles on the transient engine testing facility with inputs based on military driving conditions. The developed controller can be scaled up for armoured fighting vehicle engines.
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