Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2006. / The quest for higher efficiency of the internal combustion engine will always be pursued. Increasingly stringent emission regulations are forcing manufacturers to downsize on engine displacement and increase specific power. By adding a turbocharger, the airflow throught he engine and hence the specific power can be increased.

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2005. / This study involved the modeling and verification of the finger follower valve train arrangement with the focus on the non-linear behaviour of high speed valve springs. The project was divided into three phases namely; the measuring of valve train dynamics, modeling of the valve train and the verification of the dynamic models by comparing the results from the two aforementioned two phases. Acceleration and force were measured on a running engine. A force transducer was specially developed for this purpose. Digital signal processing was used in the analysis and implementation of all measured data. The spring model was developed systematically from a solid model, into a finite element model, and finally into a dynamic model. All development steps were continually checked with experiments and calculations. The primary concept used in the spring modeling lends itself to modal analysis theory in conjunction with the superimposing of non-linearities onto a linear model. The dynamic model was verified and good correlations were found, especially at high engine speeds where valve train dynamics play an important role. Parameter adjustments could be made in the dynamic model and the effect that some engine mechanisms, such as engine oil aeration, had on the valve train dynamics were identified. The project was concluded with a case study of a cam profile optimisation project. Dynamic problems were found that would normally not have been identified without the dynamic model.

Thesis (MScEng)--University of Stellenbosch, 2001. / ENGLISH ABSTRACT: This thesis is concerned with unsteady, one-dimensional flow, which closely mimics those found in the manifolds of internal combustion engines. The physical equations describing problems of this nature are presented and some of the important concepts introduced. These equations and concepts were verified by comparison to published results. The Method of Characteristics (MaC) for unsteady one-dimensional flow with friction and heat transfer was used to analyse the gas flow through the inlet and exhaust systems of an engine. The theoretical derivation of unsteady gas dynamic boundary conditions is presented and the integration with the unsteady pipe flow explained. A simulation flow model was developed to analyse the flow by using the Mae. Thisflow model was then incorporated into an engine simulation program, ESA,to simulate internal combustion engines and to predict the performance of a specific engine. A cam-profile model and an in-cylinder thermodynamic model are used to complete the ESAsoftware. Experimental work was done on a modified Nissan Z24/NA20 engine to evaluate the simulation model. The manifolds of the Nissan Z24/NA20 were modified to isolate one of the cylinders for a proper single cylinder model. More experimental work was done on a Volkswagen 1.6£ 8-valve and a 1.6£ 20-valve engine to obtain performance data on two inlet manifolds developed using the ESAsoftware. Performance data and pressure traces in the inlet manifold of the Nissan Z24/NA20 were recorded for comparison with the ESA software. Good correspondence was found between tested and modelled data and the differences varied between ±5% on engine performance data and pressure wave frequency predictions, and ± 10% on pressure pulse amplitudes. / AFRIKAANSE OPSOMMING: Hierdie tesis handeloor bestendige, eendimensionele vloei, wat die gasvloei in spruitstukke van binnebrandenjins naboots. Die nodige vergelykings wat hierdie tipe probleme beskryf asook van die belangrikste konsepte, word bespreek. Hierdie vergelykings en konsepte is met behulp van gepubliseerde data geverifieer. Die Metode van Karakteristieke (MVK) vir bestendige, eendimensionle vloei met wrywing en warmte oordrag, is gebruik om die gasvloei deur inlaat en uitlaat sisteme van 'n enjin te analiseer. Die teoretiese afleiding van bestendige gasdinamiese randvoorwaardes asook hul integrasie met die bestendige pypvloei, word verduidelik. 'n Simulasie vloeimodel is ontwikkelom die vloei met behulp van die metode van karakteristieke te analiseer. Hierdie vloeimodel is deel van 'n omvattende enjinsimulasie program, ESA. Dit word gebruik om binnebrandenjins te simuleer en enjinwerkverrigting te voorspel. 'n Nokprofielmodel en 'n termodinamiese ontbrandingsmodel word gebruik om die enjinsimulasie program af te rond. Eksperimentele toetse op 'n gemodifiseerde Nissan Z24/NA20 enjin is gebruik om die simulasie model te evalueer. Die spruitstukke van die Nissan Z24/NA20 is aangepas om een van die silinders te isoleer om so 'n geskikte enkelsilindermodel te skep. Verdere eksperimentele toetse is gedoen op Volkswagen 1.6£8- klep en 1.6£ 20-klep enjins. Werkverrigtingsdata is verkry op twee nuwe inlaatspruitstukke wat met behulp van die ESAsagteware ontwerp is. Werkverrigtingsdata en drukverdelingsdata in die inlaatspruitstuk van die Nissan Z24/NA20is aangeteken om te vergelyk met die resultate van die ESAsagteware. Goeie ooreenstemming is verkry tussen toets- en gemoduleerde data. Die verskille varieer tussen ±5% op enjin werkverrigtingsdata en drukpulsfrekwensie voorspellings, en ± 10%op drukpuls-amplitudes.

Thesis (MScEng)--University of Stellenbosch, 2001. / ENGLISH ABSTRACT: Statistical experimental design techniques are powerful tools that are often approached with suspicion and apprehension by experimenters. The trend is to avoid any statistically structured and designed experimentation program, and to rather use the traditional method of following ones "gut feel". This approach, more often than not, will supply a satisfactory solution, but there is so much more information availablefor the same amount of effort. This thesis strives to outline the method and application of the Taguchi methodology of experimental design. The Taguchi method is a practical, statistical experimental design technique that does not rely on the designer's knowledge of the complex statistics typicallyneeded to design experimental programs, a fact that tends to exclude design of experiments from the averageengineers' toolbox. The essence of the statistical design of experiments is this: The traditional method of varying one variable at a time and investigating its effect on an output is no longer sufficient. Instead all the input variables are varied at the same time in a structured manner. The output trends resulting from each input variable are then statisticallyextracted from the data in the midst of the variation. Taguchi method achieves this by designing experiments where every level of every input variable occurs an equal number of times with every level of every other input variable. The experimental designs are represented in orthogonal arrays that are chosen and populated by the experimenter by following a simple procedure. Four case studies are worked through in this text and, where possible, compared to the "traditional" approach to the same problem. The case studies show the additional information and time savings availablewith the Taguchi method, as well as clearlyindicating the importance of using a stable system on which to do the experiments. The Taguchi method generated more information in fewer experiments than the traditional approaches as well as allowing analysis of problems too complex to analysewithout a statisticaldesign of the experimentation procedure. / AFRIKAANSE OPSOMMING: Statistiese eksperimentele ontwerptegnieke is besonder kragtige instrumente wat baie keer met agterdog deur ekspermenteerders beheen word. Die neiging is om enige statistiese gestruktureerde and ontwerpte eksperimentele program te vermy, en om liewer die tradisionele metode, wat op 'n mens se intuïsie staatmaak, te gebruik. Hierdie benadering sal baie keer 'n bevredigende oplossing gee, maar daar is veel meer inligting vir dieselfde hoeveelheid inspanning verkrygbaar, wanneer die Taguchimetode gebruik word. Hierdie tesis strewe om die metode en toepassing van die Taguchimetodologie van eksperimentele ontwerp voor te lê. Die Taguchimetode is 'n praktiese statistiese eksperimentele ontwerptegniek .wat nie op die ontwerper se kennis van komplekse statistiek om eksperimentele programme te ontwerp berus nie. Hierdie komplekse statistiek neig ook om eksperimentele ontwerp van die gemiddelde ingenieursvaardigehede uit te sluit. Die kern van statistiese eksperimentele ontwerp is die volgende: Die tradisionele metode van een veranderlike op 'n slag te varieer om die effek op die uitset te ondersoek, is onvoldoende. In plaas daarvan, word al die insetveranderlikes gelyktydig gevarieer in 'n gestruktureered manier. Die neigings van elke veranderlike is dan statisties ontleed van die data ten midde van die variasie van al die ander veranderlikes. Die Taguchimetode bereik die ontwerpte eksperimente deur elke vlak van elke insetveranderlik in 'n gelyke aantal keer met elke vlak van elke ander insetveranderlike te varieer. Hierdie is verteenwoordig deur ortogenale reekse wat gekies en gevul is deur 'n eenvoudige wisselpatroon te volg. Vier gevallestudies is deurgewerk en, waar moontlik, vergelyk met die tradisonele siening van dieselfde probleem. Die gevallestudies wys hoe toereikbaar die additionele inligting in die Taguchimethode toepassings is. Hulle beklemtoon ook die belangrikheid van 'n stabiele sisteem waarop die eksperimente berus. Die Taguchimetode het meer inligting verskaf met minder eksperimente as die tradisionele toenaderings, en ook toegelaat dat die analise van probleme, te kompleks om te analiseer sonder om 'n statistiese ontwerp van eksperimentele prosedure te volg, opgelos kon word.

Thesis (MScEng)--University of Stellenbosch, 2003. / ENGLISH ABSTRACT: The automotive industry in South Africa is expanding as a result of pressure on the world economy that forces vehicle manufacturers to outsouree work to developing countries. In order to add value to automotive engine development, the capability to perform state-of-the-art engineering must be developed in this country. Threedimensional fluid flow simulation is one such area and is being developed in this study in order to enhance the ability to develop combustion systems. Another capability being developed at the University of Stellenbosch is the simulation of valve train dynamics. It was realised that there is a lack of research results of in-cylinder flow characteristics and how they influence combustion chamber processes. This project focuses on the investigation of two different combustion chamber geometries and how they influence the flow and combustion processes in two different combustion chambers. The aim is to gain a better understanding of combustion chamber flow as an indirect result from comparing the flow in two fundamentally different engines under similar operating conditions. The difference in the engines is that one was developed for reduced exhaust gas emissions while the other was developed to achieve high performance. The numerical simulation capability is developed in the process of achieving this goal. To achieve the above-mentioned aim, a literature study was performed on the different combustion chamber flow characteristics and how they are influenced by different configurations. An experimental method of measuring combustion characteristics is studied in order to establish the ability to perform the latter. Theory of numerical flow simulation is also studied with this same goal in mind. Experimental testing is performed and combustion analysis is done on the results. In conjunction to the experimental work, numerical flow simulations are performed on the two different combustion chambers. The results from experimental testing and numerical simulations have shown that obstructions in the flow into the combustion chamber, together with a port configuration that cause flow around the longitudinal axis of the cylinder, increases the rate at which fuel burns in the combustion chamber and thereby reduce the production of toxic emissions from the engine. The study also proved that reducing resistance to flow increases the amount of air that is breathed by the engine and thereby results in increased torque generation. Through this study, opportunities for further research are identified. The results of the study can be used when new combustion systems are developed, especially in the light of ongoing tightening of emission regulations. The contribution to numerical flow simulation capabilities developed in this study add value to the ability to develop new combustion systems in the future, especially when complimented by some of the further research topics identified. / AFRIKAANSE OPSOMMING: Die motorbedryf in Suid-Afrika is besig om vinnig te ontwikkel as direkte gevolg van druk op die wêreldekonomie wat internasionale motorvervaardigers forseer om werk na ontwikkelende lande uit te kontrakteer. Hoogs gesofistikeerde ingenieurstegnieke moet ontwikkel word in Suid-Afrika met die doelom waarde toe te voeg aan enjin ontwikkeling. Drie-dimensionele vloei simulasie is een van hierdie vermoëns en word tydens hierdie studie ontwikkelom die verbrandingstelsel ontwikkelings-vaardighede te bevorder. Nog 'n vaardigheid wat tans ontwikkel word aan die Universiteit van Stellenbosch is die vermoë om nok-en-klepstelsel dinamika te simuleer. Daar bestaan egter 'n leemte in navorsingsresultate van vloei eienskappe binne in die verbrandingsruim en hoe dit verbrandingsruim prosesse beïnvloed. Die projek fokus dus op 'n ondersoek van twee verskillende geometriese konfigurasies van die verbrandingsruim en hoe dit die vloei- en verbrandingsprosesse in die twee konfigurasies beïnvloed. Die doel is om 'n beter begrip te ontwikkel van verbrandingsruim prosesse as 'n indirekte gevolg van die vergelyking tussen twee fundamenteel verskillende enjins onder eenderse bedryfstoestande. Die verkil tussen die twee enjins is dat een ontwikkel is met die doelop verlaagde uitlaatgas emmissies en die ander ontwikkel is om verbeterde werkverrigting. Die numeriese simulasie vermoë is ontwikkel in die proses om die doel te bereik. Om bogenoemde doel te bereik is 'n literatuurstudie gedoen wat verskillende vloeieienskappe in die verbrandingsruim ondersoek, asook hoe dit deur verskillende konfigurasies beïnvloed word. 'n Eksperimentele metode III die bepaling van verbrandingseienskappe is ook bestudeer met die doelom laasgenoemde uit te voer. Teorie aangaande numeriese vloei simulasie is ook bestudeer met bogenoemde doel. Eksperimentele toetse is gedoen en verbrandingsanalise uitgevoer op die resultate. In kombinasie met die eksperimentale werk is numeriese simulasies van die prosesse in die twee verbrandingsruim konfigurasies uitgevoer. Die resultate van die eksperimentele toetse en numeriese simulasies toon dat obstruksies in die vloei na die verbrandingsruim, gesamentlik met die poort konfigurasie wat veroorsaak dat lug om die longitudinale as van die silinder vloei, die tempo waarteen die lug-brandstof mengsel verbrand verhoog en sodoende die vrystelling van skadelike uitlaatgasse na die atmosfeer verminder. Die studie het ook getoon dat die vermindering van weerstand teen vloei, die hoeveelheid lug wat in die verbrandingsruim invloei vermeerder en sodoende die wringkrag wat deur die enjin gelewer word verhoog. Deur die studie is verdere navorsingsgeleenthede uitgewys. Die resultate van die studie kan gebruik word in die ontwikkeling van nuwe verbrandingstelsels, veral in die lig van verstrengende regulasies rakende uitlaatgas emmissies. Die bydrae tot numeriese vloei simulasie vermoëns ontwikkel in hierdie studie voeg waarde toe tot die vermoë om nuwe verbrandingstelsels te ontwikkel, veral wanneer dit gekomplimenteer word met van die verdere navorsingsonderwerpe wat geïdentifiseer is.

O presente trabalho tem como escopo validar qualitativa e quantitativamente o ensaio de swirl em cabeçotes de motores Diesel realizado de maneira contínua, comparando-o com o padrão estático amplamente aplicado na indústria no controle de qualidade deste componente. A modificação metodológica do ensaio permite ensaios muito mais velozes do que os atuais, podendo, com todas as verificações necessárias, ser extensível a uma linha de montagem, permitindo controle de qualidade diretamente após o processo de usinagem do fundido ou antes de montar o cabeçote no bloco do motor. O presente trabalho apresenta a metodologia aplicada para o tratamento do problema bem como os resultados obtidos até o momento, indicando também os que ainda serão obtidos. No escopo do projeto, apresenta-se de maneira sucinta todo o procedimento utilizado para as simulações estáticas e transiente dos métodos de medição a partir do método do volume finitos de um código comercial, destacando a metodologia para determinação das malhas, seleção dos modelos e esquemas de discretização utilizados, destacando por fim uma comparação entre diferentes aberturas de válvula do ensaio estático e os primeiros resultados da simulação com abertura de válvula ao longo do tempo de simulação. Do ponto de vista experimental, descreveu-se o equipamento utilizado bem como as adaptações realizadas, principalmente no que tangem a automação do controle de válvula, no escopo do presente projeto, apresentando por fim alguns resultados do ensaio contínuo na bancada em comparação com o estático. Os ensaios e simulações numéricas estática e transientes apresentaram coerência em seus resultados. As simulações, quando comparadas entre si e com os resultados do PIV, mostram que os perfis de escoamento são bastante parecidos em todas as situações, o que permite concluir que existe a possibilidade de se realizar o ensaio de swirl de forma dinâmica para esta configuração específica. / The present work aims to validate qualitatively and quantitatively the swirl test in diesel engine heads performed continuously, comparing it with the static standard widely applied in industry in the quality control of this component. The methodological modification of the test allows for tests much faster than the current ones and can be extensible to an assembly line, allowing quality control directly after the cast machining process or before mounting the engine block. The present work presents the applied methodology for the treatment of the problem as well as the results obtained so far, also indicating the ones that will be obtained. In the scope of the project, the whole procedure used for the static and transient simulations of the measurement methods based on the finite volume method of a commercial code is presented, highlighting the methodology for determining the meshes, selection of models and schemes of discretization. At last, a comparison between different valve openings of the static test and the first results of the simulation with valve opening during the simulation time will be presented. From the experimental point of view, the equipment used was described, as well as the adaptations made, mainly in what concerns the automation of valve control, within the scope of the present project. Some results of the continuous test in the bench are presented and compared with the static ones. The static and dynamic tests and simulations presented good coherence among their results. The simulations, when compared one with each other and to the PIV test results, showed great similarities among the in-cylinder flow velocity profiles, what might lead to the conclusion that it is possible to test cylinder heads dynamically, at least with the presented configuration.

Governments across the world are implementing legislation for ever more strict limits for vehicle emissions; combined with customer expectations for growing levels of performance and equipment, automotive manufacturers face a significant challenge. With the aim of meeting this challenge, downsizing is an established trend in passenger car engine development. However, since downsizing is commonly achieved through pressure charging (turbocharging, for example), the associated benefits in improved fuel economy and emissions are often obtained at the expense of engine dynamic response, and, consequently, vehicle driveability. This thesis presents predominantly simulation-based research into a novel combined charging system comprising a conventional turbocharger used in conjunction with a declutchable supercharger driven through a CVT. An initial investigation using this system in place of a variable geometry turbocharger on an already downsized passenger car diesel engine demonstrated greatly increased low speed torque as well as improved dynamic response. A downsizing project that involved replacing a naturally aspirated gasoline engine with a highly boosted engine with 40% of the original displacement formed the basis for more extensive investigations. Although it was unable to produce the low speed transient response of the naturally aspirated engine, in tip-in tests the CVT-supercharger system was shown to achieve the target torque much quicker than an equivalent system with a fixed supercharger drive ratio. However, balancing this with good fuel efficiency for the initial part load period was a complex trade-off. In vehicle acceleration simulations the CVT-supercharger system did not outperform the fixed drive ratio configuration, but on the CVT system the boost limit was reached at an early stage during the transients. Thus there may be potential to include an ‘over-boost’ facility, allowing boost pressure to temporarily exceed normal steady state limits in order to improve transient performance and bring it closer to that of the baseline vehicle. It is suggested that the CVT-supercharger provides the best flexibility for calibration and compromise between performance and fuel efficiency, perhaps incorporating different user-selectable modes (such as ‘economy’ and ‘sport’ modes).

A rápida evolução do mercado automotivo, em função de maiores restrições sobre as emissões, impulsionou a utilização de várias alternativas para melhorias dos motores diesel, entre elas as mudanças nos seus componentes com o auxílio de ferramentas de modelagem e a utilização de combustíveis alternativos. As características dos combustíveis afetarão a queima e, assim, alteram os resíduos do processo de combustão. Novos combustíveis podem também ser utilizados como uma alternativa para veículos de gerações anteriores com o intuito de reduzir as emissões. Este estudo mostra os efeitos da utilização do Biodiesel B20 e do Biodiesel Amyris em motores de combustão interna. Para isso, foram realizados testes de motores em salas dinamométricas, e seus resultados confrontados e discutidos. Além disso, são abordados os efeitos do combustível no processo da combustão. Esta Dissertação está concentrada, principalmente, na emissão de NOx e de material particulado, que são poluentes mais restritivos perante a Legislação brasileira de emissões CONAMA P7. / The fast evolution of the automotive market, in light of the more restrictive emissions requirements, spurred several alternatives for improvements of diesel engines; among them, changes in the engine components with the aid of modeling tools and use of alternative fuels. The fuel characteristics will affect the combustion and thus combustion process residues. New fuels also can be an alternative for vehicles of previous generations of emissions, aiming of reducing them. This study shows the effects of the B20 biodiesel and Amyris biodiesel in diesel engines. Engine tests were held in dynamometric testing cells and their results were compared and discussed. The effects of the different fuels in the combustion process are also discussed. This work is focused mainly in NOx (nitrogen oxide) and particulate matter emissions, which are more restrictive pollutants regarding the Brazilian emissions legislation CONAMA P7.

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.

The widespread use of finite element models in assessing system dynamics for noise, vibration, and harshness (NVH) evaluation has led to recognition of the need for improved procedures for correlating models to experimental results. This study develops and applies a methodology to correlate an experimental modal analysis with a finite element modal analysis of valve trains in IC-engines. A pre-test analysis procedure is employed to guide the execution of tests used in the correlation process. This approach improves the efficiency of the test process, ensuring that the test article is neither under nor over-instrumented. The test-analysis model (TAM) that results from the pre-test simulation provides a means to compare the test and the model both during the experimental approach and during the model updating process. The validity of the correlation methodology is demonstrated through its application on the valve train of a single overhead cam (SOHC) engine.