The internal combustion engine is synonyms with the automobile since its invention in late 19th century. The internal combustion engine today is far more advanced and efficient compared to its early predecessors. An intense competition exists today amongst the automotive OEMs in various countries and regions for stepping up sales and increasing market share. The pressure on automotive OEMs to reduce fuel consumption and emission is enormous which has lead to innovations of many variations in engine and engine-related technologies. However, IC engines are in existence for well more than a century and hence have already evolved to a highly refined state. Changes in IC engine are therefore largely incremental in nature. A deterrent towards development of an engine configuration that is significantly different from its predecessor is the phenomenal cost involved in prototyping. Thus, the only viable alternative in exploring new engine concepts and even optimizing designs currently in operation is through extensive use of CAE. In light of published work in the field of analysis of IC engines, current research effort is directed towards development of a rational methodology for arriving at a weight-optimized engine design, which simultaneously meets performance of various attributes such as thermal, durability, vehicle dynamics and NVH. This is in contrast to the current methodology adopted in industry, according to which separate teams work on aspects of engine design such as combustion, NVH (Noise, Vibration and Harshness), acoustics, dynamics, heat transfer and durability. Because of the involvement of heterogeneous product development groups, optimization of an engine for weight, which can have a significant impact on its power-to-weight ratio, becomes a slow process beset with manual interventions and compromise solutions. Thus, following the traditional approach, it is quite difficult to claim that an unambiguous weight-optimized design has been achieved. As a departure from the practiced approach, the present research effort is directed at the deployment of a single multi-physics explicit analysis solver, viz. LS-DYNA - generally known for its contact-impact analysis capabilities, for simultaneously evaluating a given engine design for heat transfer, mechanical and thermal loading, and vibration. It may be mentioned that only combustion analysis is carried out in an uncoupled manner, using proven phenomenological thermodynamic relations, to initially arrive at mechanical and thermal loading/boundary conditions for the coupled thermo-mechanical analysis. The proposed methodology can thus be termed as a semi-integrated technique and its efficacy is established with the case study of designing a single cylinder air-cooled diesel engine from scratch and its optimization.

The master thesis deals with the design of a single-cylinder diesel piston internal combustion test engine by modifying the initial mass-produced three-cylinder engine. The first part of the thesis is devoted to the introduction to the problems of diesel and experimental single cylinder engines. Subsequent chapters focus on the adaptation of the baseline engine itself, including balancing of inertial forces. Furthermore, the crankshaft operability is checked, including the determination of safety against high-cycle fatigue. The last chapter deals with the design of the connection of the adapted unit to the dynamometer.

Forskning inom motorutveckling bedrivs för att möta kommande emissionskrav och samtidigt minska bränsleförbrukningen. Kommande förbud mot dieseldrivna fordon planeras i flera städer runt om i världen. Alternativa bränsle som exempelvis naturgas ses som en lovande ersättning även för tunga fordon. Metan som är huvudkomponenten av naturgas har en fördelaktigt förhållande mellan väte och kol vilket gör den attraktiv för CO2-reducering. Hur som helst, bränslets låga cetantal och den höga aktiveringsenergin som krävs för att tända naturgas förutsätter tändstiftsantändning.En fördel av att använda en encylindrig motor inom forskning är möjligheten att studera fenomen utan negativa gasväxlingsinteraktioner från intilliggande cylindrar. Jämfört med en fullmotor möjliggörs även ett snabbare utbyte av motordelar samt lägre bränsleförbrukning.Fokus för detta examensarbete var genomförandet av ett flexibelt bränslesystem för en tändstiftsantänd encylindrig motor. Motorn är en tändstiftsantänd Scania 9 liters som modifieras för encylinder körning. Flexibilitet som t.ex. laddningshomogenitet, selektiv fyllning av inloppsporter och förberedelser för direktinsprutning av flytande bränsle realiserades. För enkel användning är motorn styrd av en eftermarknadsmotorstyrenhet som använder ett användarvänligt grafiskt gränssnitt för ändring av driftsparametrar. Säkerhetshänsyn vid blandning av gasformiga bränsle och luft långt innan inloppsporterna har implementerats. / Most of the fundamental research in internal combustion engines is driven by the ever-increasing stringency of emissions regulations along with the need for increased fuel economy. The proposed ban on diesel vehicles in several cities around the world combined with extensive availability, has made natural gas a promising substitute even for heavy-duty applications. The high hydrogen-to-carbon ratio of methane, the major component of natural gas, makes it attractive from an emissions reduction perspective. CO2 emissions from natural gas combustion are particularly low. However, the low cetane number and high activation energy required to ignite natural gas, requires spark-ignition.In a research setting, it is often advantageous to have a single cylinder engine. The main benefit is the ability to study phenomena without adverse interactions which multi-cylinder operation may cause. This is especially important for gas-exchange studies. Quicker replacement of parts and lower fuel consumption are secondary benefits.The focus of this thesis was the implementation of a flexible fueling system for a single cylinder spark-ignited engine. The engine is a Scania 9-liter spark-ignited engine modified for single cylinder operation. Flexibility in terms of charge homogeneity, selective intake port filling and provisions for liquid fuel direct injection have been provided. For ease of use, the engine is controlled by an aftermarket engine control unit with a graphical user interface for configuration. Safety considerations when mixing gaseous fuels and air well upstream of the intake ports have been implemented.

Bio-fuels, being the primary alternative to the fossil fuels, used in the internal combustion engines are subjected to constant development. The development of alternative Ethanol Diesel (ED95) formulations at AVL Motortestcenter AB has demanded a test facility capable of evaluating the combustion quality of these specimens. A test cell capable of evaluating fuels operating on the compression ignition concept was required for this reason. The aim of this thesis is to develop a high pressure fuel delivery system for a single cylinder test cell engine. The literature review conducted offered knowledge on stages involved in the development of the fuel and the operation of high pressure fuel systems for engines operating on the Diesel concept. Knowledge was acquired on phenomenon such as pressure fluctuations and information regarding engine test cells was familiarised. Scania's XPI fuel system being the designated fuel system for the test cell was studied and adaptations required for its implementation in the single cylinder test cell was investigated. Based on the information acquired, recommendations for the set up of the high pressure fuel system for the single cylinder test cell engine are mentioned. / Förnyelsebara biobränslen är det primära alternativet till fossila bränslen för användning i interna förbränningsmotorer och är under ständig utveckling. För den fortsatta utvecklingen av etanoldiesel (ED95) genom provning av nya formuleringar vid AVL Motortestcenter AB krävs ett lämplig testupplägg. Förbränningskvalitetsutvärderingen kräver en avancerad testcell där bränslets förbränningsegenskaper kan utvärderas. Målet med detta arbete var att utveckla ett högtrycksbränslesystem lämpligt för en singelcylindrig forskningsmotor som arbetar enligt kompressionständningsprincipen (dieselprincipen). Litteraturstudien samlade kunskap om bränsleutveckling samt kunskap om dieselmotorers högtrycksbränslesystemen, dess uppbyggnad och utmaningar. Kunskap om fenomen som tryckoscillationer och kavitation i bränslesystem samt förståelse för motorprovcellers uppbyggnad införskaffades. Scanias XPI bränslesystem, som forskningsmotorns högtrycks- bränslesystem ska efterlikna, studerades och adaptioner för att passa till encylinderkörningar i provcell utvärderades. Baserat på informationen ges rekommendationer på hur Scanias XPI system kan implementeras och justeras för att fungera i AVL’s singelcylinderprovcell.

This master thesis project was performed in collaboration with Scania CV AB, Engine Materials group. The purpose with the project was to investigate different ceramic TBC (Thermal Barrier Coating) thermal insulation properties inside the combustion chamber. Experimental testing was performed with a Single-Cylinder engine with TBC deposited on selected components. A dummy-valve was developed and manufactured specifically for this test in order to enable a water cooling system and to ease the testing procedure. The dummy-valve consists of a headlock, socket, valve poppet and valve shaft. Additionally, a copper ring is mounted between the cylinder head and the valve poppet to seal the system from combustion gases. Thermocouples attached to the modified valve poppet and valve shaft measured the temperature during engine test to calculate the heat flux. The TBCs consisted of three different materials: 7-8% yttrium-stabilized zirconia (8YSZ), gadolinium zirconia and lanthanum zirconia. The 8YSZ TBC was tested as standard, but also with microstructural modifications. Modifications such as pre-induced segmented cracks, nanostructured zones and sealed porosity were used. The results indicated that the heat flux of 8YSZ-standard, 8YSZ-nano and 8YSZ-segmented cracks was in level with the steel reference. In the case of 8YSZ-sealed porosity the heat flux was measured higher than the steel reference. Since 8YSZ-standard and 8YSZ-sealed porosity are deposited with the same powder it is believed that the high heat flux is caused by radiative heat transfer. The remaining samples have had some microstructural changes during engine testing. 8YSZ-nano had undergone sintering and its nanostructured zones became fewer and almost gone after engine testing leading to less heat barrier in the top coat of the TBC. However, for 8YSZ-segmented cracks and gadolinium zirconia lower heat flux was measured due to the appearance of horizontal cracks. These cracks are believed to act as internal barriers as they are orientated perpendicular to the heat flow. During long-time (5 hour) engine tests the 8YSZ-standard exhibited the same phenomena: a decrease in heat flux due to propagation of horizontal cracks. One-dimensional heat flux was not achieved and the main reason for that was caused by heating and cooling of the shafts outer surface. However, the dummy-valve system has proven to be a quick, easy and stable to perform tests with a Single-Cylinder engine. Both water-cooling and long-time engine tests were conducted with minor issues. The dummy-valve has been further developed for future tests. Changes to the valve shaft are the most remarkable: smaller diameter to reduce heat transfer and smaller pockets to ensure better thermocouple positioning. Another issue was gas leakage from the combustion chamber through the copper ring and valve poppet joint. The copper ring will be designed with a 1 mm thick track to improve sealing, hence better attachment to the valve poppet.