Today the environmental issues are a lot on the agenda and the environmental awareness are more and more common. New laws and restrictions on engines emissions are enforced and the demand on the engines gets higher and tougher. This leads to the engine testing playing a more crucial part than ever. Engine tests are done using an engine dynamometer. The dynamometer loads the engine by, in many different ways, absorbing the power and torque generated by engine. The most important functions of a dyno are to convey the power from the engine to the dyno, to load the engine, to measure the power and torque generated by the engine and to remove the excess heat that is generated.  Husqvarna is a Swedish company that produces garden and forest cutting tools, their most famous products are their chainsaws. Husqvarna does an extensive amount of engine testing, long time testing, functional testing and field testing. Some functional tests, such as start-ability after use is done in a climate chamber where the humidity and temperature can be set. Today, loading a chainsaw in -25 °C is a problem due to the fact that the most used dynamometer at Husqvarna is a water brake that freezes in minus degrees. This master thesis will answer the question on how to, for small engine, simulate the load that occurs during normal use of the engine and how to develop a dynamometer suitable for Husqvarna’s needs? The focus when developing the dynamometer will lie on solving the problem with minus degrees and having a good detachable coupling between the dyno and the chainsaw. The result is a hydraulic oil dynamometer. A hydraulic pump is attached to the guide bar and chainsaw using a detachable key way coupling and bearings. By controlling restriction of the flow in the hydraulic system the load can be controlled and also ultimately the RPM of the chainsaw. The hydraulic oil works fine in the minus degree as long as the right oil with the right viscosity range is used although a problem with the small chainsaws are that they are not reaching the full RPM in -25 °C. Mainly because of the backpressure created by the components in the system. This can be solved by minimizing the hydraulic systems total flow restriction.   However this problem doesn’t affect the testing methods as long as the chainsaw easily can be disconnected and freed from the dynamometer and then be run to full RPM which the coupling between the pump and chainsaw enables.

The automated testing of internal combustion engines is a field of considerable importance. This thesis describes a novel area in the form of dynamic testing. The investigation represents an original approach to the problem with which the author believes he has developed a new concept in engine testing. The resulting information, combined with an appreciation of the latest developments in automation equipment technology, has lead to a review of the requirements of a generalised engine test system together with an outline of the way in which it could be implemented. The automated engine test beds used during the work are described. The conventional methods of testing internal combustion engines are reviewed and a generalised approach to automating them proposed. This then leads to the suggestion of a new method using dynamic testing techniques specially evolved in the course of the work. On the basis of this the implementation of a dynamic full-load power curve as a replacement for its steady state equivalent was pursued. The second major use of dynamic techniques is for exhaust emission cycles. Both dynamic (USEPA Smoke Cycle) and steady-state (USEPA 13 Mode Cycle) cycles were performed. In the case of the former, outer digital loop techniques were used to improve control response. In performing the above work, use was made of both analog and digital simulation techniques for development purposes. This work was also extended by the development of a simulation of a material handling system to enable the control and optimisation of a production test facility to be studied. The testing methods associated with automated fault diagnosis are also analysed. On the basis of the above work an engine test system task analysis was generated and this new concept used to plan a microprocessor based engine test automation scheme.

Engine development today is driven by cost, performance and government regulations. Customers want cars and trucks to consume less fuel, last longer, pollute less and be safer. Several of the requirements have tribological associations. For example, product longevity can be improved by lowering friction and using more wear-resistant components. In recent decades, the use of new coating application procedures and techniques has produced remarkably advances in relation to cutting tools. The process temperature at which coatings are applied has been lowered to below 200 oC. Thus it is now possible to coat low-alloy temper-sensitive steels, which are widely used in the automotive industry in machine elements such as gears, bearings and cam followers. The aim of this work has been to investigate the possibility of using sputtered amorphous carbon coatings to reduce friction and prevent wear in engine components, and specifically in valve train components. Test equipment simulating near-normal running conditions for the valve mechanism has been developed and used to test standard and coated valve components. The mechanism has also been analysed and simulated numerically. The results show a low velocity difference between the injector cam lobe and the roller, except for a short interval at the top dead centre of the rocker arm. In that region the slip increases significantly at higher speeds due to inertial forces. A three-dimensional finite element parameter study of the coating thickness, elastic modulus, asperity contact size and wavelength has shown that tensional stresses at the coating surface increase significantly when asperity contacts approach and interact. Testing of different thicknesses in rolling contact, together with finite element stress analysis, showed that a higher tensional stress level through the coating thickness increases the possibility of cracks propagating down to the interlayer and causing delamination of the coating. Tests with a rapid load increase on two carbon coatings show no transition from mild to more severe wear. Instead the contact is dimensioned by the plastic deformation of the underlying substrate.

<p>Engine development today is driven by cost, performance and government regulations. Customers want cars and trucks to consume less fuel, last longer, pollute less and be safer. Several of the requirements have tribological associations. For example, product longevity can be improved by lowering friction and using more wear-resistant components. In recent decades, the use of new coating application procedures and techniques has produced remarkably advances in relation to cutting tools. The process temperature at which coatings are applied has been lowered to below 200 oC. Thus it is now possible to coat low-alloy temper-sensitive steels, which are widely used in the automotive industry in machine elements such as gears, bearings and cam followers. </p><p>The aim of this work has been to investigate the possibility of using sputtered amorphous carbon coatings to reduce friction and prevent wear in engine components, and specifically in valve train components. Test equipment simulating near-normal running conditions for the valve mechanism has been developed and used to test standard and coated valve components. The mechanism has also been analysed and simulated numerically. The results show a low velocity difference between the injector cam lobe and the roller, except for a short interval at the top dead centre of the rocker arm. In that region the slip increases significantly at higher speeds due to inertial forces. </p><p>A three-dimensional finite element parameter study of the coating thickness, elastic modulus, asperity contact size and wavelength has shown that tensional stresses at the coating surface increase significantly when asperity contacts approach and interact. Testing of different thicknesses in rolling contact, together with finite element stress analysis, showed that a higher tensional stress level through the coating thickness increases the possibility of cracks propagating down to the interlayer and causing delamination of the coating. Tests with a rapid load increase on two carbon coatings show no transition from mild to more severe wear. Instead the contact is dimensioned by the plastic deformation of the underlying substrate.</p>

This thesis details an in investigation of two problems arising during the testing of a jet engine in a test cell, namely the formation and ingestion of vortices and the generation and propagation of infrasound. Investigation involved the use of computational fluid dynamic as well as analytical tools. The author extended the work of previous researchers by investigating the effect when a suction inlet in surrounded by four walls, (as it is in a test cell). A previously suspected but not documented small region of unsteady vortex was discovered to lie between the steady vortex and no vortex regions. The preferential attachment of the vortex, when formed, to a particular surface was investigated and a low velocity region near that surface has been proven as a possible cause. A cell bypass ratio > 90% was found to be necessary to avoid the formation of vortices in typical situations. Parametric studies (conducted cetaris paribus) on four different geometries and flow parameters were also conducted to determine how they affected the vortex formation threshold. Boundary layer thickness on the vortex attachment surface, upstream vorticity, size of suction inlet was found to have a direct relationship with probability of vortex formation whereas Reynolds number of flow was found to have an inverse relationship. Three hypotheses regarding the generation and propagation of infrasound in test cells were analysed. The first hypothesis states that the fluctuating of flow within the test cell led to a periodic fluctuation of pressure. The second hypothesis predicts a change in flow conditions can leads to a change in the acoustic reflection characteristics of the blast basket perforates. The final hypothesis proposes that changing engine location and size of augmenter, can lead to a reduction in the slip velocity between the engine exhaust jet and the cell bypass flow thus reducing the engine jet noise. The first hypothesis has been disproved using CFD techniques, although the results are as yet inconclusive. The second and third hypotheses have been proven to be potentially feasible techniques to be employed in the future. The changes proposed in the final hypothesis are shown to reduce the engine jet noise by up to 5 dB.

In the automotive industry engines are regularly tested and evaluated by running them for a prolonged time under controlled conditions; environmental conditions, engine load, and drive cycle. These tests are performed in an engine test cell; a computer controlled environment with mechanical fittings and sensors to facilitate the testing of an engine. Our goal was to develop a software suite that provides a distributed graphical interface to the data acquisition and control systems of an engine cell. As we found existing systems to be inadequate in providing a distributed interface, we designed and developed a light weight flexible software suite to remotely, over a network, observe and control the parameters in an engine cell. We used the Fast Light Toolkit (FLTK) GUI library, with networking sockets and process threads to establish the software architecture of the engine test system. Through use of process threads, the client architecture divides tasks into network data sending and receiving, local channel synchronization, and interface operation. Networking sockets used in network data sending and receiving facilitate synchronization of each clients' channel storage and host's channel data. The FLTK GUI library produces visual interactive components of the interface for invoking interactions. Distributed interfacing allows display and modification of the engine cell's operation remotely in locations where relocating an engine cell is not feasible. These locations, such as demonstrations to distant clients and meeting rooms, display the current status of the engine cell through its interfaces without requiring migration of the engine cell to the specified rooms. / Thesis / Master of Applied Science (MASc)

Orientador: Paulo Roberto Gardel Kurka / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-11T04:00:47Z (GMT). No. of bitstreams: 1 Mello_ClaudioCoelhode_M.pdf: 11766357 bytes, checksum: 5f2659f4a4238bfbfaa4dd0e10c50790 (MD5) Previous issue date: 2006 / Resumo: This study evaluates the existing technology of converting the various residues in oil refineries and compares with the new technology of that the Grupo Combustíveis Alternativos (GCA), in conjunction with Petrobras and CENPES would apply to the conversion of the residue of the Vacuum distillation. Also studied is one of the components of the reactor Fast Pyrolysis developed in the GCA during phase two of Presat. This component is the injector and its study helps improve the reactor built for stage three from Presat. For the study were assembled two spout equipment, the first directed to study the behavior of the flow of droplets inside the reactor and the second for the purpose of measuring the distribution of droplets generated by the size of the nozzle / Abstract: This study evaluates the existing technology of converting the various residues in oil refineries and compares with the new technology of that the Grupo Combustíveis Alternativos (GCA), in conjunction with Petrobras and CENPES would apply to the conversion of the residue of the Vacuum distillation. Also studied is one of the components of the reactor Fast Pyrolysis developed in the GCA during phase two of Presat. This component is the injector and its study helps improve the reactor built for stage three from Presat. For the study were assembled two spout equipment, the first directed to study the behavior of the flow of droplets inside the reactor and the second for the purpose of measuring the distribution of droplets generated by the size of the nozzle / Mestrado / Projeto Mecanico / Mestre em Engenharia Mecânica

A novel turbo rotary engine, operating according to a novel thermodynamic cycle, having an efficient compression phase, a limited temperature combustion phase followed by a long power extraction phase is designed. Thermodynamic and structural design and analysis of this novel engine is carried out and two prototypes are manufactured according to these analysis. High performance figures such as torque, power and low specific fuel consumption are calculated. Also the component tests of the manufactured prototypes are completed and their results are demonstrated.

Le travail de cette thèse s'inscrit dans le cadre du développement de la méthodologie CRONE (Commande Robuste d'Ordre Non Entier) multivariable. Il porte plus précisément sur la simplification de sa mise en oeuvre pour la synthèse de régulateurs multivariables robustes, avec une application au contrôle de bancs d'essais moteur haute dynamique, notamment ceux développés par l'entreprise D2T. Le premier chapitre présente les différents types de bancs d'essais, leur fonctionnement et leur problématique. Le deuxième chapitre présente tout d'abord une modélisation physique simple des bancs d'essais qui en permet ensuite leur simulation, puis est dédié à leur identification fréquentielle avec une application à un banc d'essais équipé d'un moteur Diesel. Le troisième chapitre présente la méthodologie CRONE multivariable et différents développements permettant d'en simplifier la mise en oeuvre notamment grâce à l'optimisation d'un nouveau paramètre. Illustrant ces développements, la boite à outils CRONE multivariable qui a été développée est alors utilisée pour la synthèse de la loi de commande d'une maquette de banc d'essais constituée de deux moteurs asynchrones. Finalement, le quatrième chapitre est dédié à la validation des développements présentés par leur application à un banc d'essais haute dynamique équipé d'un moteur Essence. Ce chapitre présente également les différents outils logiciel développés pour faciliter l'intégration de la méthodologie CRONE full MIMO aux produits D2T. / The work presented in this Thesis is part of the CRONE (robust control with fractional integration order) multivariable methodology development. It deals with the simplification of the robust multivariable control system implementation with application to the control of high dynamic engine test-benches, including those developed by the D2T company. The first chapter introduces different kind of test-benches and gives a general idea about how those systems work while explaining their problems. While the first part of chapter II presents a simple method for test-benches modeling which then allows their simulation, the second part is dedicated to their frequency-domain system identification. The defined identification procedure is applied to a test-bench equipped with a Diesel engine. The third chapter presents the CRONE multivariable methodology and different developments to simplify its use. Reflecting these developments, the developed CRONE multivariable toolbox is used to design a control system for a test-bench consists of two asynchronous motors. The fourth chapter is dedicated to validate the presented work by applying these developments to a high dynamic test-bench with a spark ignition engine. This chapter presents the various software tools developed to simplify the implementation to D2T products of the CRONE full MIMO methodology.

This master thesis is part of a bigger project issued by AVL with the purpose to design a high pressure compression ignition fuel system for their single cylinder test cell at their facility in Södertälje. Typically compression-ignition fuel tests are being run within an operating pressure range of 500-2400 bar, but this system has to be able to run with pressures up to 3500 bar. The project was intended to be carried out by two participants where this master thesis covers the evaluation of how fuel consumption rates shall be measured in the system described above as well as how the fuel shall be conditioned. The selected concept for measuring fuel consumption rate was based on measuring the mass flow on the low-pressure side of the system with a Coriolis flowmeter. The chosen temperature sensor for monitoring the temperature on the high-pressure side was a K-type thermocouple which would be directly connected to the fuel rail in the system. A bleeder was selected on the basis that it had been used in one of AVL's old test cells. A heat exchanger could not be chosen. However a rough estimation of the capacity needed for a heat exchanger was calculated for future reference. The methodology used to develop a concept was based on the engineering project process taught to students at Karlstad University. First a project plan was made followed by a solution-independently expressed product specification including a specification of requirements and QFD-matrix. Several concepts were generated for measuring the fuel consumption by evaluating different measuring principles, available components, possible positions of the components within the system and combinations with different fuel supply concepts. Less extensive methods were used for the remaining tasks in the detailed engineering phase of the project. The concepts were compared using Pugh's analysis and a concept was selected in collaboration with AVL. The majority of the objectives for this master thesis could be successfully carried out. The documentation and drawings requested by the client, manufacturing of the system, implementation and validation into the test cell could not be done due to lack of time. This, along with the selection of a heat exchanger and low-pressure thermocouple was left for future work.