This thesis deals with the adjustment racing turbocharged SI engine. The main objective was to design a suitable type of turbocharger and changes needed for proper engine operation. The upgrades were based on the stock Mitsubishi 4G63T engine.

More stringent Euro 6 and LEV III emission standards will immediately begin execution on 2014 and 2015 respectively. Accurate air/fuel ratio control can effectively reduce vehicle emission. The simulation of engine dynamic system is a very powerful method for developing and analysing engine and engine controller. Currently, most engine air/fuel ratio control used look-up table combined with proportional and integral (PI) control and this is not robust to system uncertainty and time varying effects. This thesis first develops a simulation package for a port injection spark-ignition engine and this package include engine dynamics, vehicle dynamics as well as driving cycle selection module. The simulations results are very close to the data obtained from laboratory experiments. New controllers have been proposed to control air/fuel ratio in spark ignition engines to maximize the fuel economy while minimizing exhaust emissions. The PID control and fuzzy control methods have been combined into a fuzzy PID control and the effectiveness of this new controller has been demonstrated by simulation tests. A new neural network based predictive control is then designed for further performance improvements. It is based on the combination of inverse control and predictive control methods. The network is trained offline in which the control output is modified to compensate control errors. The simulation evaluations have shown that the new neural controller can greatly improve control air/fuel ratio performance. The test also revealed that the improved AFR control performance can effectively restrict engine harmful emissions into atmosphere, these reduce emissions are important to satisfy more stringent emission standards.

With the depletion of petroleum based fuels and the corresponding concerns of national energy security issues, natural gas as an alternative fuel in IC engine applications has become an attractive option. Natural gas requires minimum mixture preparation, and is chemically stable, both of which make it a suitable fuel for homogeneous charged compression ignition (HCCI) engines. Compared to petroleum based fuels, natural gas produces less green-house emissions. However, natural gas is hard to auto-ignite and therefore requires a higher compression ratio, some amount of intake heating, or some type of pre-ignition. In addition, natural gas usually has large differences in fuel composition from field to field, which adds more uncertainties for engine applications. The current study determines the auto-ignition characteristics, engine performance, and nitric oxides emissions as functions of major operating parameters for a natural gas fueled HCCI engine, and determines differences relative to gasoline fueled HCCI engines which have been studied for many years. These tasks have been done using both zero- and multi-dimensional engine simulations. By zero-dimensional simulation, the effects of varying equivalence ratios, engine speeds, compression ratio, EGR level, intake pressure and fuel compositions are determined and analyzed in detail. To be able to account for the in-cylinder inhomogeneous effect on the HCCI combustion, multi-zone models coupled with cold-flow CFD simulations are employed in addition to the single-zone model. The effects of non-homogeneous temperature and equivalence ratio stratification on the ignition timing, combustion phasing, and emissions formation have been studied and discussed. Finally, the preliminary two-dimensional axial-symmetric CFD simulations have been conducted to study the in-cylinder temperature and the species distributions, which provide better visualization of the natural gas auto-ignition process.

The efficiency of an internal combustion (IC) engine is governed by the thermodynamic cycle underpinning its operation. The thermodynamic efficiency of these devices is primarily determined by the temperature gradient created during the compression process. The final conversion efficiency also known as brake thermal efficiency (BTE) of IC engines, however, also depend on other processes associated with its operation. BTE is a product of the combustion, thermodynamic, gas-exchange, and mechanical efficiencies. The improvement of BTE through maximation of any one of the four efficiencies is reduced by its implication of the other three. Split-cycle engine provides an alternative method of improving the engine efficiency through over-expansion of combustion gases by transferring it to a cylinder of greater volume. The operation of split-cycle engines is based on either the Brayton or the Atkinson Cycles. Atkinson Cycle has been demonstrated in IC engines without the split-cycle architecture but is limited by the reduced energy density. Double Compression Expansion Engine (DCEE) provides a method of accomplishing the Atkinson Cycle without the constraints faced in conventional engine architectures. DCEE splits the compression and expansion processes in a vertical manner that enables the use of larger cylinder volumes for over-expansion as well as first-stage compression without much friction penalties. The present thesis explores the thermodynamic cycle of this novel engine architecture using well-validated 1-dimensional engine models solving for gas-exchange, real gas properties, and heat transfer provided in the GT-Power software tool. The effect of compression ratio, rate of heat addition, sensitivity to design and modeling parameters was assessed and contrasted against conventional engine architecture. The synergies of combining low-temperature combustion (LTC) concepts with DCEE was investigated using simulation and experimental data. DCEE relaxes many constraints placed the operation of an engine in Homogenous Charge Compression Ignition (HCCI) mode. The limitations of adopting Partially Premixed Combustion (PPC) concept is also alleviated by the DCEE concept. BTE improvement of above 10% points is achievable through the DCEE concept along with possibility to achieve very low emissions through use of LTC concepts and new after-treatment methods uniquely available to the DCEE.

A presente dissertação trata do projeto de um motor de combustão interna de quatro tempos, ciclo Otto, destinado à categoria de competição Formula SAE, adequado ao mercado brasileiro. Uma extensa pesquisa bibliográfica e de mercado foi realizada para o direcionamento do projeto, além de análises experimentais para obtenção de dados. No estudo experimental foi utilizado um motor monocilíndrico de 300 cc de deslocamento volumétrico, arrefecido a ar, oriundo de uma motocicleta comercial atual, denominado nesta dissertação como \"motor base\". Esse motor foi instalado em uma bancada de dinamômetro e instrumentado de forma a permitir sua avaliação mecânica e termodinâmica. Estudos de desempenho, análises de combustão e emissões também foram realizados, incluindo utilização de etanol, variações da razão ar/combustível e sobrealimentação. Igualmente, foram feitos ensaios experimentais de componentes específicos utilizados no projeto. Os dados experimentais foram utilizados como parâmetros para o projeto mecânico do novo motor Formula SAE, e para a modelagem e simulação do motor base em fluidodinâmica computacional unidimensional (CFD-1D), que foi utilizada como ferramenta auxiliar do projeto. O escopo do projeto mecânico do motor foi restrito ao bloco, virabrequim e alguns componentes de integração, uma vez que todos os demais componentes foram extraídos do motor base e de outros motores presentes no mercado nacional. O motor Formula SAE foi projetado em ambiente computacional (CAD), sendo que para o projeto mecânico do bloco e virabrequim foram realizadas simulações computacionais estruturais, utilizando o método dos elementos finitos (FEA), para verificação da distribuição de tensões nos componentes projetados. O novo motor Formula SAE apresentou vantagens significativas em relação aos custos para aquisição de peças de montagem e reposição, e proporcionou flexibilidade de montagem e operação. / The present dissertation addresses the design of a 4 stroke Otto cycle internal combustion engine dedicated to Formula SAE student program and fitted to the Brazilian market. An extensive literature review and a market benchmark were performed, in order to provide guidance to the project, and experimental analysis for data acquisition. For the experimental study, a 300 cm3 single cylinder air cooled motorcycle engine has been used, taken from a motorcycle currently in production, available in Brazilian market, called in this dissertation as \"base engine\". This engine has been installed in a dynamometer test bench and instrumented in order to allow its mechanical and thermodynamic evaluation. Performance, combustion and emissions analysis were also performed, including ethanol fueling, air/fuel ratio variation and supercharging. Experimental tests with specific engine components were performed to provide necessary design data. The experimental data were used as input parameters for the mechanical design, as well as for modeling and simulation of the base engine on one-dimensional computer fluid dynamics, which was used as an auxiliary tool for this project. The scope of mechanical design of this engine was restrict to the crankcase, crankshaft and some assembly components, since all other components were taken from the base engine and other engines from the national market. The design was assisted by computer aided design (CAD). In order to verify the crankcase and crankshaft mechanical design regarding stress distribution, computational structural analysis have been performed using the finite element method (FEA). The new Formula SAE engine presented significant advantages regarding purchasing costs of parts for assembly and maintenance, and provided assembly and operation flexibility.

A presente dissertação trata do projeto de um motor de combustão interna de quatro tempos, ciclo Otto, destinado à categoria de competição Formula SAE, adequado ao mercado brasileiro. Uma extensa pesquisa bibliográfica e de mercado foi realizada para o direcionamento do projeto, além de análises experimentais para obtenção de dados. No estudo experimental foi utilizado um motor monocilíndrico de 300 cc de deslocamento volumétrico, arrefecido a ar, oriundo de uma motocicleta comercial atual, denominado nesta dissertação como \"motor base\". Esse motor foi instalado em uma bancada de dinamômetro e instrumentado de forma a permitir sua avaliação mecânica e termodinâmica. Estudos de desempenho, análises de combustão e emissões também foram realizados, incluindo utilização de etanol, variações da razão ar/combustível e sobrealimentação. Igualmente, foram feitos ensaios experimentais de componentes específicos utilizados no projeto. Os dados experimentais foram utilizados como parâmetros para o projeto mecânico do novo motor Formula SAE, e para a modelagem e simulação do motor base em fluidodinâmica computacional unidimensional (CFD-1D), que foi utilizada como ferramenta auxiliar do projeto. O escopo do projeto mecânico do motor foi restrito ao bloco, virabrequim e alguns componentes de integração, uma vez que todos os demais componentes foram extraídos do motor base e de outros motores presentes no mercado nacional. O motor Formula SAE foi projetado em ambiente computacional (CAD), sendo que para o projeto mecânico do bloco e virabrequim foram realizadas simulações computacionais estruturais, utilizando o método dos elementos finitos (FEA), para verificação da distribuição de tensões nos componentes projetados. O novo motor Formula SAE apresentou vantagens significativas em relação aos custos para aquisição de peças de montagem e reposição, e proporcionou flexibilidade de montagem e operação. / The present dissertation addresses the design of a 4 stroke Otto cycle internal combustion engine dedicated to Formula SAE student program and fitted to the Brazilian market. An extensive literature review and a market benchmark were performed, in order to provide guidance to the project, and experimental analysis for data acquisition. For the experimental study, a 300 cm3 single cylinder air cooled motorcycle engine has been used, taken from a motorcycle currently in production, available in Brazilian market, called in this dissertation as \"base engine\". This engine has been installed in a dynamometer test bench and instrumented in order to allow its mechanical and thermodynamic evaluation. Performance, combustion and emissions analysis were also performed, including ethanol fueling, air/fuel ratio variation and supercharging. Experimental tests with specific engine components were performed to provide necessary design data. The experimental data were used as input parameters for the mechanical design, as well as for modeling and simulation of the base engine on one-dimensional computer fluid dynamics, which was used as an auxiliary tool for this project. The scope of mechanical design of this engine was restrict to the crankcase, crankshaft and some assembly components, since all other components were taken from the base engine and other engines from the national market. The design was assisted by computer aided design (CAD). In order to verify the crankcase and crankshaft mechanical design regarding stress distribution, computational structural analysis have been performed using the finite element method (FEA). The new Formula SAE engine presented significant advantages regarding purchasing costs of parts for assembly and maintenance, and provided assembly and operation flexibility.

Master’s thesis is focused on creating a suitable methodology for determining the parameters of the electronic control unit of the engine. Discusses how the measurement of input data into the methodology, the basic description of its functions and display the resulting values. It includes evaluation of applicability of the methodologies and the real parameters when compared with the parameters established on the basis of established methodology.

The full text will be available at the end of the embargo period: 4th Aug 2025

El modelado se ha convertido en los últimos años en una herramienta esencial en el diseño de motores de combustión interna alternativos, ya que permite reducir considerablemente el tiempo y los costes de desarrollo. Las metodologías de diseño clásicas se basan en la fabricación de prototipos y la realización de pruebas de ensayo y error. Actualmente, la mayoría de estas pruebas han sido sustituidas por cálculos numéricos, de modo que sólo las opciones de diseño más prometedoras se prueban en realidad en banco motor. Durante años, los códigos unidimensionales de dinámica de gases en el dominio del tiempo han sido suficientes para modelar tanto las prestaciones y el consumo del motor como el ruido de admisión y escape. Sin embargo, para un nivel más exigente de diseño, una representación 1D puede no ser suficiente para describir con precisión el flujo en ciertos elementos. Esto es especialmente importante en el caso de silenciadores, donde la hipótesis unidimensional sólo se puede aplicar a geometrías simples. En el caso de las uniones de conductos es la existencia de estructuras tridimensionales de flujo complejas lo que establece el límite de la aplicabilidad de una descripción simple cero-dimensional. En vista de estas limitaciones, la primera opción sería el uso de un modelo de dinámica de fluidos computacional (CFD); sin embargo, su aplicación conllevaría un tiempo de cálculo excesivo. Una posible solución de compromiso viene dada por los modelos cuasi-3D, basados en esquemas tridimensionales, pero con ciertas simplificaciones capaces de reducir significativamente el tiempo de cálculo sin afectar excesivamente a la precisión. Tales soluciones se han convertido en estándar en los códigos comerciales y se han aplicado con éxito a los silenciadores, tanto para excitaciones acústicas en el régimen lineal como en condiciones reales de motor, típicamente no lineales. Esta tesis tiene como objetivo el desarrollo de un nuevo método numérico cuasi-3D en una malla escalonada, basado en la simplificación de la ecuación de la cantidad de movimiento, para ser incluido en un código unidimensional existente. Tal método, sin embargo, no está libre de inconvenientes. En particular, se ve afectado por la aparición de oscilaciones no físicas, especialmente en gradientes de presión significativos. De la revisión bibliográfica se determina que este comportamiento es típico en esquemas de segundo orden y se puede ver acentuado por las simplificaciones adoptadas. Tras estudiar las posibles soluciones aplicables a este problema, se desarrollan tres limitadores de flujo diferentes, basados en las metodologías MDT, FCT y TVD. Una vez definido el método numérico y asegurada su estabilidad, es necesario desarrollar las condiciones de contorno adecuadas que permitan su utilización. Con este objetivo, se desarrollan las condiciones de pulso de presión de entrada y de extremo anecoico, los cuales permiten simular un banco de impulso. No hay que olvidar, sin embargo, que el objetivo final es la conexión con un código unidimensional, por lo que hay que comprobar que el método numérico cuasi-3D creado es compatible con los unidimensionales existentes, mostrando algunos resultados preliminares. Finalmente, con el método ya completamente operativo, se procede a su validación en las aplicaciones para las que ha sido diseñado principalmente, las cuales son, modelado de silenciadores y uniones de conductos. Para el caso de los silenciadores, se modelan dispositivos de complejidad creciente, pasando por geometrías de sección constante hasta sistemas con geometrías reales. Los resultados obtenidos se validan con otras herramientas tanto lineales como no lineales. En el caso de las uniones de conductos, el objetivo principal es el de establecer el potencial del nuevo método numérico frente a los tradicionales unidimensionales, por lo que los resultados de ambos se comparan con datos experiment / Engine modelling has become an essential tool in the design of internal combustion engines, allowing considerable reductions in development time and cost. Classical design methodologies are based on prototype manufacturing and trial-and-error tests, but currently, most of those tests have been replaced by numerical computations, so that only the most promising design options are actually tested on engine bench. For years, one-dimensional gas dynamics codes in the time domain have offered sufficiently good solutions for modelling both engine performance and intake and exhaust noise. However, for a more demanding level of design, a 1D representation may not be sufficient to describe accurately the flow in certain elements. This is especially important in the case of silencers. In the case of duct junctions, the existence of complex 3D flow structures is what sets the applicability limit for a simple zero-dimensional description. In view of these limitations, the first option would typically be the use of a computational fluid dynamics (CFD) model; however, the application of such a model to a complete intake or exhaust system entails an excessive computational time. A possible compromise solution is given by quasi-3D models, based on three-dimensional schemes, but with certain simplifications able to significantly reduce the calculation time without excessively affecting the accuracy. Such solutions have become standard in commercial codes and have been successfully applied to silencers with perforated tubes and absorbing material, both in the linear acoustic regime and in real engine conditions, typically non-linear. The objective of this thesis is the development a new quasi-3D numerical method in a staggered-grid, based on the simplification of the momentum equation, to be included in an existing one-dimensional code. Such method however, is not hassle free. In particular, it is affected by the appearance of non-physical oscillations, specially near significant pressure gradients. From the literature review it is determined that this behaviour is typical among second-order schemes and it can be aggravated by the simplifications adopted. After researching the possible solutions to face this problem, three different flux limiters are developed, based on the MDT, FCT and TVD methodologies. In the case of the two latter methods, its effectiveness is well established for finite differences schemes, thus defining a clear improving line for quasi-3D models. Once the numerical method is defined and its stability assured, proper boundary conditions that allow its use must be developed. With this objective, a pressure pulse inlet and an anechoic termination boundary condition are developed, which allow the simulation of an impulse test rig. It should not be forgotten, however, that the ultimate objective is the connection with a one-dimensional code, therefore the compatibility of the quasi-3D numerical method created with the existing one-dimensional methods has to be tested, showing some preliminary results. Eventually, with a fully operative method, the validation process for the applications which it has been mainly developed for, takes place, namely, mufflers and duct junctions modelling. In the case of mufflers, increasingly complex devices are modelled, from constant section geometries to real geometry systems. The results obtained are validated with both linear and non-linear tools. In the case of duct junctions, the main objective is to establish the potential of the new numerical method against the traditional one-dimensional schemes, consequently, results from both approaches are compared to experimental measures, obtaining promising results. / El modelatge s'ha convertit en els últims anys en una eina essencial en el disseny de motors de combustió interna alternatius, ja que permet reduir considerablement el temps i els costos de desenvolupament. Les metodologies de disseny clàssiques es basen en la fabricació de prototips i la realització de proves d'assaig i error. Actualment, la majoria d'aquestes proves han sigut substituïdes per càlculs numèrics, de manera que només les opcions de disseny més prometedores es proven en realitat en banc motor. Durant anys, els codis unidimensionals de dinàmica de gasos en el domini del temps han sigut suficients per a modelar tant les prestacions i el consum del motor com el soroll d'admissió i escapament. No obstant això, per a un nivell més exigent de disseny, una representació 1D pot no ser prou per a descriure amb precisió el flux en certs elements. Açò és especialment important en el cas de silenciadors, on la hipòtesi unidimensional només es pot aplicar a geometries simples. En el cas de les unions de conductes és l'existència d'estructures tridimensionals de flux complexes el que establix el límit de l'aplicabilitat d'una descripció simple zero-dimensional. En vista d'estes limitacions, la primera opció seria típicament l'ús d'un model de dinàmica de fluids computacional (CFD); no obstant això, l'aplicació comporta un temps de càlcul excessiu. Una possible solució de compromís ve donada pels models quasi-3D, basats en esquemes tridimensionals, però amb certes simplificacions capaços de reduir significativament el temps de càlcul sense afectar excessivament la precisió. Tals solucions s'han convertit en estàndard en codis comercials i s'han aplicat amb èxit als silenciadors, tant per a excitacions acústiques en el règim lineal com en condicions reals de motor, típicament no lineals. Aquesta tesi té com a objectiu el desenvolupament d'un nou mètode numèric quasi-3D en una malla escalonada, basat en la simplificació de l'equació de la quantitat de moviment, per a ser inclòs en un codi unidimensional existent. Tal mètode, però, no està lliure d'inconvenients. En particular, es veu afectat per l'aparició d'oscil·lacions no físiques, especialment en gradients de pressió significatius. De la revisió bibliogràfica es determina que aquest comportament és típic en esquemes de segon ordre i es pot veure accentuat per les simplificacions adoptades. Després d'estudiar les possibles solucions aplicables a aquest problema, es desenvolupen tres limitadors de flux diferents, basats en les metodologies MDT, FCT i TVD. En el cas dels dos últims mètodes, la seua efectivitat està ben establida per als esquemes de diferències finites, la qual cosa definix una clara via de millora per als models quasi-3D. Una vegada definit el mètode numèric i assegurada la seua estabilitat, és necessari desenvolupar les condicions de contorn adequades que permeten la seua utilització. Amb aquest objectiu, es desenvolupen les condicions de pols de pressió d'entrada i d'extrem anecoic, els quals permeten simular un banc d'impuls. No cal oblidar que l'objectiu final és la connexió amb un codi unidimensional, per la qual cosa cal comprovar que el mètode numèric cuasi-3D creat és compatible amb els unidimensionals existents, mostrant alguns resultats preliminars. Finalment, es procedix a la seua validació en les aplicacions per a les que ha sigut dissenyat principalment, les quals són, modelatge de silenciadors i unions de conductes. Per al cas dels silenciadors, es modelen dispositius de complexitat creixent, passant per geometries de secció constant fins a sistemes amb geometries reals. Els resultats obtinguts es validen amb altres eines tant lineals com no lineals. En el cas de les unions de conductes, l'objectiu principal és el d'establir el potencial del nou mètode numèric front als unidimensionals tradicionals, per la qual cosa els resultats d'ambdós es comparen amb dades experim / Hernández Marco, M. (2018). A non-linear quasi-3D model for air management modelling in engines [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/103683 / TESIS

The master thesis contains a theoretical part with the topic of valve train. It contains measured data and their processing. The processed data are used to create the 1D engine’s simulation. Valve train’s parameters were modified for increased power and torque. Contained two variants of changes can serve as guide for final draft because of next adjustments.