Control of the Intake Air Dynamics on a Single-Cylinder Engine, to Replicate Multi-Cylinder Engine Dynamics

2015 ◽  
Author(s):  
John J. Moskwa ◽  
Mark B. Murphy
Keyword(s):  
Heat Transfer ◽  
Gas Dynamics ◽  
Test System ◽  
Charge Motion ◽  
Single Cylinder ◽  
Powertrain Control ◽  
University Of Wisconsin ◽  
Single Cylinder Engine ◽  
Control Research ◽  
Significant Step

Single-cylinder test engines are used extensively in engine research, and sparingly in engine development, as an inexpensive way to test or evaluate new concepts or to understand in-cylinder motion or combustion. They also allow good access to the cylinder for instrumentation, however, these single-cylinder engines differ significantly in rotational dynamics, gas intake dynamics, heat transfer dynamics, dynamic coupling between cylinders, and in other areas. Charge motion within the cylinder, even during the closed period differs from the multi-cylinder engine because of the differences in both instantaneous flow and momentum. Researchers in the Powertrain Control Research Laboratory (PCRL) at the University of Wisconsin-Madison have developed single-cylinder engine transient test systems that control the instantaneous dynamic cylinder boundary conditions to replicate those in the target multi-cylinder engine. The overall goal is to exploit the benefits of the single-cylinder engine, while eliminating the negative aspects of this device, and to have the single-cylinder “think” it is dynamically operating within a multi-cylinder engine. This paper describes the latest developments in controlling the intake gas dynamics of the single-cylinder engine to meet these goals. A combination of both rotary and proportional valves are used to accurately replicate the instantaneous intake airflow that exists in the multi-cylinder engine, including during transients. A Fourier-based approach instead of the previous time-based trajectory control is used to accomplish these goals. This is a third generation of intake air simulator (IAS3) that is a significant step forward in both simplifying the system, and in significantly expanding the operating envelop of the engine to include the full engine operating range of the multi-cylinder engine. A brief introduction of the entire transient test system will show the reader how rotational, heat transfer, and gas dynamics are controlled, and how the IAS3 fits into this overall system.

IC Engine Transient Heat Transfer System Hardware and Simulation

2007 ◽  
Author(s):  
Stephen J. Klick ◽  
Brian Krosschell ◽  
John J. Moskwa
Keyword(s):  
Heat Transfer ◽  
Control Strategies ◽  
Test System ◽  
Transient Heat Transfer ◽  
Intake Manifold ◽  
Ic Engine ◽  
Loop Control ◽  
Single Cylinder ◽  
Powertrain Control ◽  
Control Research

One of the ongoing goals of the Powertrain Control Research Laboratory (PCRL) at University of Wisconsin-Madison is to expand the capabilities of the single-cylinder internal combustion research engine by bringing its operation closer to that of its multi-cylinder counterpart. The PCRL has already replicated the rotational dynamics and intake manifold dynamics of a multi-cylinder engine on a single-cylinder research engine. This paper covers the development of an addition to the single-cylinder test system that will allow the replication of transient heat transfer that normally occurs in a multi-cylinder engine from the engine to the coolant. This system will include physical hardware as well as real time hardware-in-the-loop control strategies using MATLAB/Simulink and dSPACE software.

Comparative Test Results From a Virtual Multi-Cylinder Engine Transient Test System

2010 ◽  
Author(s):  
Derek A. Mangun ◽  
John J. Moskwa
Keyword(s):  
Heat Transfer ◽  
Real Time ◽  
Gas Dynamics ◽  
Test System ◽  
Rotational Dynamics ◽  
Test Bed ◽  
Single Cylinder ◽  
Single Cylinder Engine ◽  
Emission Testing ◽  
Hil Simulation

Researchers in the Powertrain Control Research Laboratory (PCRL) at the University of Wisconsin-Madison have developed and built a single-cylinder engine transient test system which accurately replicates the dynamic operation of a multi-cylinder engine. Using hardware-in-the-loop (HIL) simulation, the multi-cylinder engine’s transient (a) rotational dynamics, (b) intake gas dynamics, and (c) heat transfer dynamics are reproduced in real time using several patented subsystem designs. These subsystems produce the dynamic boundary conditions that would be present for a given cylinder within a multi-cylinder engine, based on either real-time model execution or predetermined command trajectories (e.g. measured data). In addition to replicating the effects of the virtual cylinders, the test system facilitates extension of the single-cylinder engine capabilities beyond typical steady-state regime limitations. The primary goals of this project are to retain the attributes of the single-cylinder engine that are most beneficial while overcoming the problems which cause the single-cylinder engine to operate differently than a multi-cylinder engine. This system represents a very unique test bed for controlling and understanding the influences of changes in the engine design and control, solves several of the problems associated with the operation of a single-cylinder engine, and allows rapid transient testing with slew rates in excess of 10,000 rpm/s. A virtual powertrain and vehicle model can be incorporated into this system so that standardized vehicle emission testing can be conducted with this single-cylinder engine system (e.g., FTP and other transient drive cycle tests). This paper reports the research findings of the performance effects achieved by including the multi-cylinder dynamic interactions during HIL simulation using only single-cylinder engine hardware. The target engine used for this study is the Ford 3.0 L V-6 SI engine, and both the multi- and single-cylinder engines are resident in the PCRL. By directly comparing the operation of this virtual multi-cylinder transient test system with its actual multi-cylinder engine counterpart, the influences of the included dynamics are documented. Evaluations include comparative data from rotational dynamics and intake gas dynamics, as well as the ability to control heat transfer dynamics and conduct exhaust emission testing.

Engine Start Simulation on an Engine Transient Test System: Hardware and Controls

2007 ◽  
Author(s):  
Brian D. Krosschell ◽  
Stephen J. Klick ◽  
John J. Moskwa
Keyword(s):  
Cold Start ◽  
Testing Procedure ◽  
Test System ◽  
Stiff System ◽  
Powertrain Control ◽  
Single Cylinder Engine ◽  
Control Research ◽  
High Bandwidth ◽  
Very High ◽  
Engine Start

The goal of this research is to use a hydrostatic transient dynamometer combined with new control techniques to replicate multi-cylinder engine dynamics which occur while the engine is started by an electric starting system. The transient engine dynamometer test system in the Powertrain Control Research Laboratory (PCRL) uses a torque tube and extremely stiff driveline in order to provide a very high bandwidth of torque actuation. The design and nature of this low inertia, stiff system requires that a standard electrical starting system be omitted. One of the objectives of this research was to assemble a new engine on the hydrostatic dynamometer and model the starting dynamics which occur during an engine cold start. The other objective was to verify and compare data collected by the PCRL and Ford to validate testing. This information will then be used in support of development of a cold start testing procedure on the single-cylinder engine transient test system in the PCRL.

A Hardware-in-the-Loop Transient Diesel Engine Test System for Control and Diagnostic Development

2001 ◽  
Author(s):  
C. Jason Tartt ◽  
John J. Moskwa
Keyword(s):  
Diesel Engine ◽  
State Of The Art ◽  
Catalytic Converter ◽  
Test System ◽  
Hardware In The Loop ◽  
Powertrain Control ◽  
University Of Wisconsin ◽  
Control Research ◽  
Transient Emissions ◽  
The University

Abstract This paper describes the design and capabilities of a state-of-the-art diesel engine transient test system, which has been developed and built in the Powertrain Control Research Laboratory (PCRL) at the University of Wisconsin - Madison. The system includes a hydrostatic transient dynamometer capable of approximately 300 Hz actuation bandwidth, which is integrated with a dynamic vehicle drivetrain model that runs in real time. This hardware-in-the-loop (HIL) system simulates dynamic torque loading on the engine while performing an FTP, NEDC, J10.15, or any other drive cycles. The dynamometer system is complemented with transient emissions instrumentation to evaluate the state and composition of engine feed gases, and pre and post catalytic converter gases. Included in this paper are details of the design philosophy, why a hydrostatic design was used, specifics on the hardware of the system, as well as experimental data from the system.

A Transient Single Cylinder Test System for Engine Research and Control Development

2005 ◽  
Author(s):  
John L. Lahti ◽  
Matthew W. Snyder ◽  
John J. Moskwa
Keyword(s):  
Test System ◽  
Intake Manifold ◽  
Test Accuracy ◽  
Test Configuration ◽  
Single Cylinder ◽  
Cylinder Test ◽  
Single Cylinder Engine ◽  
Wide Range ◽  
Reduce Development Time ◽  
High Bandwidth

A transient test system was developed for a single cylinder research engine that greatly improves test accuracy by allowing the single cylinder to operate as though it were part of a multi-cylinder engine. The system contains two unique test components: a high bandwidth transient hydrostatic dynamometer, and an intake airflow simulator. The high bandwidth dynamometer is used to produce a speed trajectory for the single cylinder engine that is equivalent to that produced by a multi-cylinder engine. The dynamometer has high torque capacity and low inertia allowing it to simulate the speed ripple of a multi-cylinder engine while the single cylinder engine is firing. Hardware in loop models of the drivetrain and other components can be used to test the engine as though it were part of a complete vehicle, allowing standardized emissions tests to be run. The intake airflow simulator is a specialized intake manifold that uses solenoid air valves and a vacuum pump to draw air from the manifold plenum in a manner that simulates flow to other engine cylinders, which are not present in the single cylinder test configuration. By regulating this flow from the intake manifold, the pressure in the manifold and the flow through the induction system are nearly identical to that of the multi-cylinder application. The intake airflow simulator allows the intake runner wave dynamics to be more representative of the intended multi-cylinder application because the appropriate pressure trajectory is maintained in the intake manifold plenum throughout the engine cycle. The system is ideally suited for engine control development because an actual engine cylinder is used along with a test system capable of generating a wide range of transient test conditions. The ability to perform transient tests with a single cylinder engine may open up new areas of research exploring combustion and flow under transient conditions. The system can also be used for testing the engine under conditions such as cylinder deactivation, fuel cut-off, and engine restart. The improved rotational dynamics and improved intake manifold dynamics of the test system allow the single cylinder engine to be used for control development and emissions testing early in the engine development process. This can reduce development time and cost because it allows hardware problems to be identified before building more expensive multi-cylinder engines.

A Transient Hydrostatic Dynamometer for Single Cylinder Engine Research With Real Time Multi-Cylinder Dynamic Simulation

2003 ◽  
Author(s):  
John L. Lahti ◽  
Steven J. Andrasko ◽  
John J. Moskwa
Keyword(s):  
Low Cost ◽  
Test System ◽  
Engine Operation ◽  
Single Cylinder ◽  
Driving Cycles ◽  
Vehicle Load ◽  
Single Cylinder Engine ◽  
High Bandwidth ◽  
State Regime ◽  
Dynamometer Test

A new high-bandwidth transient hydrostatic dynamometer test system has been developed that accurately replicates multi-cylinder engine operation using a single-cylinder research engine. Single-cylinder engines are typically used for research because of their low cost and good cylinder accessibility for instrumentation and optics. This dynamometer maintains these advantages while dramatically improving transient and low speed testing capabilities. The system also incorporates hardware-in-the-loop models for simulation of other components that would typically be present in a vehicle application. These models include: adjoining cylinders and ancillary components in the engine, the transmission, driveline, and vehicle load. Utilizing these models it is possible to replicate actual driving cycles. This high-bandwidth transient dynamometer extends the test capabilities of single-cylinder research far beyond the traditional steady state regime, enabling transient speed single-cylinder engine research while providing single-cylinder engine operation that is comparable to the multi-cylinder engine.

Single cylinder engine transient test system

2006 ◽  
Vol 40 (1/2/3) ◽  
pp. 196 ◽  
Author(s):  
John J. Moskwa ◽  
John L. Lahti ◽  
Matthew W. Snyder
Keyword(s):  
Test System ◽  
Single Cylinder ◽  
Single Cylinder Engine

Laser-Spark Ignition Testing in a Natural Gas-Fueled Single-Cylinder Engine

2004 ◽  
Author(s):  
Michael McMillian ◽  
Steven Richardson ◽  
Steven D. Woodruff ◽  
Dustin McIntyre
Keyword(s):  
Natural Gas ◽  
Spark Ignition ◽  
Single Cylinder ◽  
Single Cylinder Engine ◽  
Laser Spark ◽  
Gas Fueled ◽  
Laser Spark Ignition

Turbine Split Rings Thermal Design Using Conjugate Numerical Simulation

2013 ◽  
Author(s):  
Aleksei S. Tikhonov ◽  
Andrey A. Shvyrev ◽  
Nikolay Yu. Samokhvalov
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Gas Turbine ◽  
Gas Dynamics ◽  
Thermal Condition ◽  
Fuel Efficiency ◽  
Thermal Design ◽  
Design Practice ◽  
Gas Temperature ◽  
Split Ring

One of the key factors ensuring gas turbine engines (GTE) competitiveness is improvement of life, reliability and fuel efficiency. However fuel efficiency improvement and the required increase of turbine inlet gas temperature (T*g) can result in gas turbine engine life reduction because of hot path components structural properties deterioration. Considering circumferential nonuniformity, local gas temperature T*g can reach 2500 K. Under these conditions the largest attention at designing is paid to reliable cooling of turbine vanes and blades. At present in design practice and scientific publications comparatively little attention is paid to detailed study of turbine split rings thermal condition. At the same time the experience of modern GTE operation shows high possibility of defects occurrence in turbine 1st stage split ring. This work objective is to perform conjugate numerical simulation (gas dynamics + heat transfer) of thermal condition for the turbine 1st stage split ring in a modern GTE. This research main task is to determine the split ring thermal condition by defining the conjugate gas dynamics and heat transfer result in ANSYS CFX 13.0 package. The research subject is the turbine 1st stage split ring. The split ring was simulated together with the cavity of cooling air supply from vanes through the case. Besides turbine 1st stage vanes and blades have been simulated. Patterns of total temperature (T*Max = 2000 °C) and pressure and turbulence level at vanes inlet (19.2 %) have been defined based on results of calculating the 1st stage vanes together with the combustor. The obtained results of numerical simulation are well coherent with various experimental studies (measurements of static pressure and temperature in supply cavity, metallography). Based on the obtained performance of the split ring cooling system and its thermal condition, the split ring design has been considerably modified (one supply cavity has been split into separate cavities, the number and arrangement of perforation holes have been changed etc.). All these made it possible to reduce considerably (by 40…50 °C) the split ring temperature comparing with the initial design. The design practice has been added with the methods which make it possible to define thermal condition of GTE turbine components by conjugating gas dynamics and heat transfer problems and this fact will allow to improve the designing level substantially and to consider the influence of different factors on aerodynamics and thermal state of turbine components in an integrated programming and computing suite.

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