Fast Coriolis mass flow metering for monitoring diesel fuel injection

Prism signal processing is a new recursive FIR technique that facilitates the rapid tracking of sinusoidal signals, such as those used in a Coriolis Mass Flow Meter (CMFM). A Prism-based CMFM prototype has been developed using a commercial flowtube and a dual ARM processor-based transmitter, which is capable of generating flow measurement updates at 48 kHz. This has been applied in a feasibility study to the tracking of fast (e.g. 1.5 ms) injections of diesel fuel on a laboratory rig at engine speeds of up to 4000 rpm equivalent and at fuel pressures of up to 100 MPa. Due to the high level of vibration in the system, Prism-based notch filtering is used to suppress undesired modes of flowtube vibration in the sensor signal. Individual flow pulses can be detected by the system, but the relatively long period of oscillation of the flowtube compared to the fuel injection duration results in a spreading out over time of each flow pulse measurement. More precise measurement results may be obtained using a higher frequency resonant flowtube.     

Measurement and analysis of injection characteristics among each nozzle hole within a heavy-duty diesel engine

The mass flow rate from each injector nozzle hole of a diesel engine influences the distribution, atomization, and combustion of fuel in the chamber. Thus affecting the power, the fuel economy, and the emission quality of the diesel engine. A spray momentum flux test bench was built and used to measure the injection rate from each nozzle hole of a multi-hole nozzle in this study. Selected force sensors used for data acquisition were one of the integral parts of the set-up. The influence of the force sensors’ installed position (location in the set-up) on measured results, were analyzed and the optimum position that ensures independence of the results, determined. Additionally, the effects of injection pressure, injection pulse width and injection hole diameter on the injection characteristics were also investigated. Furthermore, in this research, the reliability and robustness of Strain sensor and Piezoelectric sensors were analyzed with regards to their response. The analysis showed that, strain sensors have weak dynamic response characteristic compared to piezoelectric sensors also, the measured result obtained from strain sensors fluctuated greatly. Piezoelectric force sensor gave a more reliable and stable measurement, comparatively. The accuracy of the results were affected by the installation position of the sensors. A distance of 16 mm (between nozzle hole exit and sensor surface) was determined to be adequate for the acquisition of reliable experimental data. As the injection pressure gets higher (during injection), the rate of mass flow increased, the average cycle-to-cycle variation coefficient and nozzle-to-nozzle variability coefficient of injection quantity decreased. Hence, improving the consistency of each cycle and the uniformity of each hole. In addition, increasing the injection pulse width decreased the average cycle-to-cycle variation coefficient. Also, nozzle-to-nozzle variability coefficient had minimal or no influence with regards to injection pressure. At 80 MPa, the uniformity of injection from the multi-hole nozzle improved significantly. In summary, the larger the hole diameters, the higher the maximum value of mass flow rate and the fuel injection quantity.     

电控单体泵系统喷射延迟特性研究

燃油喷射系统延迟特性是影响电控柴油机精确正时控制的最重要因素,在EFS油泵试验台上研究了转速、喷油量这两个因素对燃油喷射系统延迟特性的影响,利用无交互双因素方差分析法对不同转速和喷油量下的起喷及停喷延迟时间样本值进行了方差分析。分别检验了转速和喷油量对喷射以及停喷延迟时间影响的显著性。结果表明:转速对起喷及停喷延迟时间的影响都非常显著,而喷油量只对停喷时间有显著影响。利用试验和方差分析结果对延迟时间补偿脉谱的标定方案进行了改进,简化了标定工作量。     

工程机械混合动力系统实验台测控系统

为了研究工程机械混合动力系统的机电耦合特性和轴系的振动特性,研制了由柴油机、电动机和液压泵共轴连接组成的工程机械混合动力系统实验台.设计了由工控机、PCI总线控制卡和组态软件组成的实验台测控系统,分析测控系统输入信号和控制信号的数量与类型,确定测控系统控制策略的设计原则和开发过程.通过在柴油机输出轴的端面布置3个加速度传感器实现柴油机工作时曲轴的振动特性,对不同负载功率下柴油机曲轴的振动特性进行试验测试.测试结果表明,柴油机曲轴的振动能量集中在径向,轴向的振动能量可忽略不计;设计的测控系统能实现混合动力系统轴系振动性能测试.     

流致振动差压式测振装置的研究

为解决管束流致振动试验中,现有接触式振动测量方法的应用局限性,提出一种基于测量受激对象换热管两侧压差脉动频率原理的测振装置,即差压式测振装置。差压式测振装置解决了传统接触式传感器对换热管外部流场的干扰问题以及安装空间受限的问题。为了验证差压式测振装置的有效性,分别进行了单管和换热管束两类流致振动测试试验。试验结果表明,差压式测振装置能在复杂的流动环境中准确捕捉到换热管受到的各类激振形式的频率,而且单管流致振动试验结果表明差压式测振装置所测得的周期性涡激振动频率与理论值偏差在5%以内。因此,差压式测振装置的研制与应用对于流致振动试验的测试以及换热管振动的长期监测均有很重要的意义。     

纳米WS2车用机油添加剂在柴油发动机中的应用效果研究

通过柴油发动机台架实验和行车实验,分析了不同工况下自制纳米WS2车用机油添加剂在柴油发动机中的应用效果。结果表明,在FC2000柴油发动机台架上应用时,纳米WS2车用机油添加剂在不同转速和不同负载下均能在一定程度上降低发动机油耗率,减少发动机尾气中NOx含量和颗粒物含量,并且当发动机转速为1 700r/min,负载为70N.m时,节油率最高为9.95%,颗粒物减排率最高为49.3%,而当发动机处于低速、高速、低载和高载等工况时,NOx减排率较高,最高达到36%;在柴油机大客车上应用时,纳米WS2车用机油添加剂使其耗油量下降约14.4%,并能在一定程度上降低发动机的运行噪声,使发动机的有害气体(NOx)排放减少34.8%～51%。综合表明纳米WS2车用机油添加剂具有良好的节能减排效果。     

车用柴油机电控系统电子控制单元的开发

开发电子控制单元是车用柴油机电控系统开发的关键。针对车用柴油机可变预行程泵电控系统,进行了电子控制单元软硬件的开发。将所开发电控单元与信号采集部分、执行机构及可变预行程泵集成后,在油泵试验台上进行了系统试验,验证了电控单元的控制性能。     

Improved hydrogen consumption detection method with flow meter of fuel cell vehicle

With the vigorous development of fuel cell vehicles, the hydrogen consumption in the driving process of fuel cell vehicles has become a major concern of automobile manufacturers and fuel suppliers. However, the measurement accuracy of flow meter in hydrogen medium cannot meet the requirements. In this paper, computational fluid dynamics software is used to simulate the velocity distribution of water and hydrogen in Coriolis flow meter with different mass flow rates without tube vibration. Aiming at the measurement error of Coriolis flow meter, a flow calibration device based on sonic nozzle was designed, and the results of measuring hydrogen mass flow by Coriolis flow meter and thermal flow meter were calibrated. Finally, the accuracy of the calibrated flow meter for measuring hydrogen mass flow under stable and dynamic conditions is tested. The test results show that the accuracy of calibrated Coriolis flow meter for hydrogen mass flow is less than ±1%, which can meet the accuracy requirements of fuel cell vehicle hydrogen consumption measurement. This study provides an important reference for the application of flow meter method in fuel cell vehicle economic evaluation method.     

高压共轨系统在135Ti柴油机上的配套设计及应用

柴油机上应用高压共轨电控供油系统在发达国家已经普及,而我国自主研发的共轨系统仍未达到规模化生产阶段.文中主要针对在国产135Ti柴油机安装高压共轨供油系统中的电控高压泵、共轨管、电控喷油器在设计、加工制造及试验中出现的问题如何解决,以及高压共轨系统的压力波动仿真模型和实验对比进行探讨.     

Floating clamping mechanism of PT fuel injector and its dynamic characteristics analysis

PT fuel injector is one of the most important parts of modern diesel engine.To satisfy the requirements of the rapid and accurate test of PT fuel injector,the self-adaptive floating clamping mechanism was developed and used in the relevant bench.Its dynamic characteristics directly influence the test efficiency and accuracy.However,due to its special structure and complex oil pressure signal,related documents for evaluating dynamic characteristics of this mechanism are lack and some dynamic characteristics of this mechanism can’t be extracted and recognized effectively by traditional methods.Aiming at the problem above-mentioned,a new method based on Hilbert-Huang transform(HHT) is presented.Firstly,combining with the actual working process,the dynamic liquid pressure signal of the mechanism is acquired.By analyzing the pressure fluctuation during the whole working process in time domain,oil leakage and hydraulic shock in the clamping chamber are discovered.Secondly,owing to the nonlinearity and nonstationarity of pressure signal,empirical mode decomposition is used,and the signal is decomposed and reconstructed into forced vibration,free vibration and noise.By analyzing forced vibration in the time domain,machining error and installation error of cam are revealed.Finally,free vibration component is analyzed in time-frequency domain with HHT,the traits of free vibration in the time-frequency domain are revealed.Compared with traditional methods,Hilbert spectrum has higher time-frequency resolutions and higher credibility.The improved mechanism based on the above analyses can guarantee the test accuracy of injector injection.This new method based on the analyses of the pressure signal and combined with HHT can provide scientific basis for evaluation,design improvement of the mechanism,and give references for dynamic characteristics analysis of the hydraulic system in the interrelated fields.     

柴油甲醇双燃料发动机动力性与经济性试验分析

介绍了柴油引燃甲醇双燃料燃烧对柴油机动力性和经济性的影响。在1台单缸、直喷、中冷柴油机上采用柴油引燃甲醇双燃料进行试验。结果显示甲醇柴油双燃料发动机在中高负荷及中高转速下运转可获得较好的燃油经济性。选择适当的引燃柴油量,双燃料发动机的动力性可以达到甚至超过原柴油的动力性。     

Precise instrumentation of a diesel single-cylinder research engine

The accuracy of any empirical result is a direct consequence of the quality of experimental setup and the strict control over testing conditions. For internal combustion engines, a large number of parameters that also exhibit complex interdependence may significantly affect the engine performance. Therefore, this work describes the essentials required to establish a high-quality diesel engine research laboratory. A single-cylinder diesel engine is taken as the fundamental building block and the requirements for all essential sub-systems including fuel, intake, exhaust, coolant and exhaust gas recirculation (EGR) are laid out. The measurement and analysis of cylinder pressure, and exhaust gas sampling/conditioning requirements for emission measurement are discussed in detail. The independent control of EGR and intake boost is also highlighted. The measurement and analysis techniques are supported with empirical data from a single-cylinder diesel engine setup. The emphasis is on providing the necessary guidelines for setting up a fully-instrumented diesel engine test laboratory.     

电控直列泵─管─阀─嘴柴油喷射系统的机液特性研究

电控直列泵─管─阀─嘴（PPVI）柴油喷射系统是一种新型的电磁阀溢流控制式直列泵喷油系统,通过分析该系统内部的压力波动过程,确定电磁控制阀在高压油路中的连接方式和最佳位置,揭示该系统的喷油量、喷油定时、喷油压力及喷油速率等方面的喷射特性,通过系统结构设计、硬件调整和软件标定解决多缸机系统的油量均匀性问题,进行电控柴油机的台架试验,表明喷射特性的可控性及其对整机综合性能的改善效果。     

重型车用柴油机氧化催化转化器耐硫性试验研究

分别燃用硫含量为320mg/kg及33mg/kg的两种柴油,在发动机台架上对氧化催化转化器(DOC)进行了185小时老化试验及欧洲稳态工况(ESC)排放。燃用33mg/kg硫含量柴油对DOC进行脱硫处理。分析老化过程中功率及排气背压变化;对比分析老化前后原机及DOC状态下的ESC排放特性;分析了脱硫过程DOC排放特性。结果表明,背压及发动机功率变化均很小;老化试验前后相比,原机排放变化很小;DOC催化转化效率有一定程度的下降;利用排气高温对DOC脱硫可恢复催化氧化能力。     

发动机缸盖螺栓拧紧力矩对机体振动的影响

针对缸盖螺栓拧紧力矩对发动机机体振动有直接影响的问题,借助必要的振动测试硬件,应用NILabVIEW开发了发动机振动数据采集与分析、数据拟合程序,以6135K-13型柴油机为研究对象,在给出振动测试方案的基础上,对采集到的振动数据进行了分析处理,研究了缸盖螺栓拧紧力矩与机体振动之间的定量关系,并对此关系进行了验证。     

Phenomenological combustion modeling of a direct injection diesel engine with in-cylinder flow effects

A cycle simulation program is developed and its predictions are compared with the test bed measurements of a direct injection (DI) diesel engine. It is based on the mass and energy conservation equations with phenomenological models for diesel combustion. Two modeling approaches for combustion have been tested; a multi-zone model by Hiroyasu et al (1976) and the other one coupled with an in-cylinder flow model. The results of the two combustion models are compared with the measured imep, pressure trace and NOx and soot emissions over a range of the engine loads and speeds. A parametric study is performed for the fuel injection timing and pressure, the swirl ratio, and the squish area. The calculation results agree with the measured data, and with intuitive understanding of the general operating characteristics of a DI diesel engine.     

柴油发动机高压共轨喷射系统介绍

近年来柴油发动机高压喷射及其电控技术的快速发展,使柴油机在油耗、功率、扭矩和尾气排放方面显现出越来越明显的优势。国外发展趋势表明,柴油机在市场中的份额将会越来越大。通过对德国西门子公司VDO汽车零部件部门研制开发的第二代采用压电石英元件的共轨喷射系统的介绍,让读者了解到柴油共轨喷射系统的最新科技与发展动向,为国内柴油发动机技术革新与生产加工提供一定的帮助。     

Numerical research on influence of structural parameters of common-rail injector on injection rate of each nozzle hole

Performance of diesel engines are influenced by fuel spray distribution, fuel-air mixture formation and combustion, which are also influenced by hole-to-hole fuel injection rate from multi-hole injectors. In this study, a customized spray momentum flux experimental test rig was used to measure the transient injection rates from a two-layered 8-hole diesel injector. The results indicated that the fuel injection rate and the cycle fuel injection quantities of the lower-layered nozzle holes were 3–15% higher than the fuel injection rates and the cycle fuel injection quantities of the upper-layered nozzle holes. A three-dimensional (3D) computational fluid dynamics (CFD) model of the two-layered 8-hole diesel injection nozzle was developed and validated by analyzing the relative error between the numerical results obtained from the model and the experimental results measured with the test injector. The simulation results showed that the relative average deviation of hole-to-hole cycle injection quantities were less than ±1%, which is the result of 5% increment in the cross-sectional area of the upper-layered holes.     

文丘里管废气再循环系统对涡轮增压柴油机性能影响的研究

加装文丘里管的高压废气再循环(Exhaust gas re-circulation,EGR)进气系统,在兼顾柴油机经济性、动力性的前提下,研究该进气系统对NO_x排放的影响。根据一款柴油机的基本结构建立柴油机一维仿真计算模型和燃烧室的三维仿真计算模型。在对模型进行标定和对柴油机原机性能仿真计算的基础上,为进气系统引入文丘里管装置并对其结构参数进行优化设计。应用所建立的一维和三维柴油机模型,对文丘里管EGR系统柴油机的经济性、NO_x和Soot排放特性进行仿真计算研究,并对计算结果进行试验验证。研究结果表明,优化设计的文丘里管EGR系统可使柴油机在欧洲稳态循环(European steady state cycle,ESC)各工况下实现较为理想的EGR率,并在不明显影响柴油机燃油经济性的前提下,使NO_x排放量下降了约28.4%。文丘里管进气系统可以实现较为理想的高压EGR循环,在柴油机ESC工况下(怠速除外)能够达到较为理想的EGR率。     

柴油机排气微粒可溶有机组分的色谱质谱分析

采用超声洗脱法对柴油机排气微粒中可溶有机组分SOF和不可溶组分IOF进行了分离,利用色谱—质谱联用技术对其中SOF的成分进行了分析。结果表明,怠速及中低负荷工况下SOF的排放量较低,随着负荷上升其排放量逐渐增加,在最大扭矩和标定转速工况下达到最高。SOF中最大的组分为烷烃,其次是芳香烃;烷烃中大部分为正烷烃,芳香烃以萘族和菲族等多环芳香烃为主。芳香烃的排放量随着负荷的上升而增加。SOF烷烃碳原子数分布的研究表明,低负荷工况下,燃油中易燃的正十四烷～正十七烷的绝大部分被烧掉,SOF中有些成分不是直接来自燃油,而是来自润滑油或燃油聚合反应的中间产物;高负荷工况下,供油量较多导致一部分正十四烷～正十七烷来不及燃烧就排出机外,SOF中还有些成分则是燃油高温裂解的产物。SOF芳香烃碳原子数分布的研究表明,高负荷工况下高碳原子数的芳香烃大都被烧掉,怠速及低负荷工况下SOF芳香烃化合物的种类相对较多。